A new hole-flanging method for thick plate by upsetting process

Flange height and lip accuracy are generally restricted by the formability of sheet metals in the conventional hole-flanging operation. A new hole-flanging process, named upsetting-flanging process, was proposed to obtain a more substantial flange from thick plate. The finite element method （FEM） with DEFORM was utilized to simulate the novel upsetting-flanging process and the influence of geometric parameters on the flange height was studied in details. A series of flanging experiments with A1050P-O were carried out to validate the FEM results, and the variations of Vicker hardness in the plate section were discussed. The results showed that the newly upsetting-flanging process revealed higher flange height and better lip accuracy than the conventional hole-flanging process, and the results between FEM simulations and experiments showed good agreement. Besides, the hardness of the plate around the flange part increases due to the work hardening after the upsetting-flanging process, which reveals better superiority in strength for the subsequent machining or assembling processes.

Prediction of crack location and propagation in stretch flanging process of aluminum alloy AA-5052 sheet using FEM simulation

The stretch flanging process is significantly affected by various geometrical,material and process parameters.The punch-die clearance and initial flange length are main parameters which have major effects on the edge crack location and strain distribution along die profile radius in the flange.Non-axisymmetric stretch flanging process of AA-5052 sheet metal blanks was carried out by numerical simulation to predict the deformation behavior of flange,location and propagation of crack in flange and to investigate the effect of punch die clearance,flange length,die and punch profile radius and friction in the stretch flanging process.The experimental investigations were made to validate the simulations results.The results reveal that the crack length increases with the increase in the flange length.It is found that the flange length has a significant effect in circumferential direction as compared with the radial direction.The punch die clearance has the most significant effect in crack propagation in comparison with flange length.The circumferential strain is found to be larger in the case of punch having the profile radius less than the die profile radius,which leads to faster edge crack propagation.A close agreement is found between simulation and experimental results in terms of location of edge crack and forming load.

Finite element and experimental analyses of cylindrical hole flanging in incremental forming

The influence of the size of pre-cut hole of blank on the formability of cylindrical hole flanging in single point incremental forming（SPIF） was studied. The flange is produced in four stages starting from 45° to 90° and employing aluminum as the test material. It is shown that the hole size has significant effects on the stress/strain distribution on the cylindrical flange. The magnitude of hoop strains increases and the flange thickness increases as the hole size increases. Likewise, the von Mises stress reduces with the increasing of hole size. Further, there is a threshold value of hole size（i.e., 80 mm） below which severe stresses occur, which lead to sheet fracturing thus failing the successful forming of cylindrical flange. Moreover, the formability reduces as the hole size is increased above the threshold size. Finally, it is concluded that 80 mm is the threshold size of hole for maximizing the formability of aluminum sheet in incremental hole flanging.

SIMULATION OF HOLE FLANGING PROCESS ON HEAVY CYLINDERS AND PARAMETER OPTIMIZATION

The forming mechanism of hole flanging on a thick-wall heavy cylinder forging is simulated by DEFORM3D. The cylinder is 4 390 mm in diameter and 390 mm in thickness. The results show that the compound deformation with bending and expanding happens in the process of hole flanging. The diameter of pre-hole of the workpiece is one of the key parameters in the process of hole flanging. The optimal diameter is obtained for reverse-conical hole of average diameter 40 mm by simulation of hole flanging process on 5 pre-holes with different diameters and 3 pre-holes with different shapes. The results can provide the scientific base for engineering application of the process.

NUMERICAL STUDY ON FLANGING AND SPRINGBACK OF STAMPED THICK METAL PLATE

A quasi-three-dimensional shell element model, which can beeffectively used to simulate the flanging and spring-backdeformation, is introduced into the independently developed CAEsoftware, KMAS, In this model, a double surface contact algorithm,which allows the gap between punch and die to change, and a spring-back treatment scheme based on finite element meshing are described.And then the flanging and spring-back deformations of the retractor'skickstand of a railcar made of stamped thick metal plate arenumerically simulated. The simulation results of flanging deformationare compared with those of international commercial software,PAM-STAMP, and experimental ones. Finally, a predicting scheme ofspring-back quantily for this problem is given.

白塞病合并主动脉瓣病变的外科手术治疗及研究进展

白塞病是一种常累及皮肤黏膜组织的罕见的免疫性血管炎性疾病,同时可影响心血管系统出现主动脉瓣病变,导致主动脉瓣反流等严重后果。传统外科手术方法具有较高的再次手术率,近年来瓣环加固或Flanged Bentall等改良手术方法的出现有助于提升此类患者的长期预后。除手术方法的创新外,围术期糖皮质激素、免疫抑制剂和生物制剂的应用也对改善此类患者的预后至关重要。本文通过总结近年来外科手术治疗白塞病合并主动脉病变的研究进展,讨论此类患者的综合治疗策略及下一步研究方向。

圆管大直径外翻边孔加工工艺设计与翻边力计算（英文）

针对现有圆管翻边工艺无法加工与圆管直径接近的外翻边孔的缺陷,提出了一种新的加工工艺方法。考虑新工艺的变形特点、加工硬化特性以及变形区的材料厚度的变化情况,推导出针对圆管翻边的翻边力计算公式。Abaqus仿真数据表明:相对于板材翻边力计算公式,本文的翻边力计算公式更加精确。

Flange Cover装置在海洋油气储运设施上的应用分析

针对Flange Cover的安装空间及形式需求;在设计中采用经验公式对Flange Cover的尺寸及结构强度进行计算,采用ANSYS及CFD等数值分析辅助工具进行模拟及核算,得出满足安装、强度及J-60防火要求的Flange Cover形式。

刚性法兰连接节点有限元分析

主要研究了钢管结构中刚性法兰连接轴心力作用的受力性能,应用大型有限元软件ANSYS进行了有限元分析,揭示了刚性法兰盘在受轴力状态下的受力特点。

Computation of the Fatigue Life of Road Wheel with Double-Layer Rubber Flange

In order to increase the fatigue life (FL) of road wheels (RW), a kind of double layer rubber flange (DLRF) is put forward. It consists of two layers of rubber, where metal wires are laid in the inner layer and the outer layer has no inlaid metal wires. Stress, strain and temperature field of DLRF were calculated with ANSYS finite element analysis (FEA) software, FL of DLRF RW was also computed with fracture mechanics fatigue theory. The results of computation indicate that the heat generated in RW's rubber flange (RF) can be reduced by the use of DLRF, and the FL of RW can be increased without affecting the mechanical intensity of RW.

Wrinkling prediction in rubber forming of Ti-15-3 alloy

Wrinkling is a common failure in the sheet metal forming of titanium owing to the relatively poor ability to shrink. It is important to predict wrinkling accurately in the sheet metal forming without costly trials. The ABAQUS/Explicit code was utilized to predict the wrinkling behavior in the sheet metal forming of Ti-15-3 alloy sheets. In terms of the comparison of wrinkling behavior between the simulation and experiment of the Fukui＇s conical cup tests at room temperature, the sensitivities of wrinkling simulation to various input parameters were evaluated comprehensively and quantitatively. Prediction of wrinkling and influence of rubber hardness on the winkling behavior in the rubber forming of convex flange were investigated quantitatively and validated by the rubber forming experiments. The excellent agreements between the simulations and the experiments conIirmed the accuracy of the prediction.

Inclusion and Bubble in Steel——A Review

The type, morphology and sources of inclusion in steels, including indigenous and exogenous inclusions, were discussed and reviewed. Indigenous inclusions are deoxidation products or inclusions precipitated during cooling and solidification of steel. Exogenous inclusions arise primarily from the incidental chemical （reoxidation） and mechanical interaction of liquid steel with its surroundings （slag entrainment and erosion of lining refractory）. Types and causes for the nozzle clogging were also summarized. Reasons for bubble formation and bubble size distribution in steels were discussed thereafter. Finally, morphology and causes of inclusion-related defects in continuously cast steel products were reviewed, such as flange cracking in cans, slag spots and line defects on strips.

Application of grey relational analysis in sheet metal forming for multi-response quality characteristics

The theory of grey systems is a new technique for performing prediction, relational analysis and decision making in many areas. In this paper, the use of grey relational analysis for optimizing the square hole flanging process parameters with considerations of the multiple response (the average flanging height, regular flanging and maximum strain) is introduced. Various flanging parameters, such as the blank inner radius rb, blank inner width B0, are considered. An orthogonal array is used for the experimental design. Multiple response values are obtained using finite element analysis (FEA). Optimal process parameters are determined by the grey relational grade obtained from the grey relational analysis for multi-performance characteristics (flanging height, regular flanging and maximum strain). Analysis of variance (ANOVA) for the grey relational grade is implemented. The results showed good agreement with the experiment result. Grey relational analysis can be applied in multiple response optimi-zation designs.

Experimental Research on Structural Behaviors of Glulam I-Beam with a Special-Shaped Section

In order to enhance the bearing capacity of structural components,save materials,and reduce cost,a glued laminated timber(glulam)I-beam that is theoretically suitable for engineering application was proposed.In this study,18 glulam specimens were fabricated using larch dimension lumber and resorcinol-formaldehyde resin.Four-point bending tests were carried out to compare the ultimate bearing capacity,strain,and deflection of various specimens.The results showed that:(1)The typical failure mode at bending is the web shear failure parallel to grain.Before the failure,cracks and sounds appear at the beam web,which represent the sudden brittle failure.(2)The cross-sectional strain of glulam beam changed linearly with the beam height,indicating that the plane section assumption was basically established.(3)Stiffener could improve the initial flexural stiffness of glulam beam,which experiences an increase of 28.21%.Larger the shear span ratio,smaller the initial flexural stiffness.The initial flexural stiffness improves by 10-23.5%with the increase in the thickness of the lower flange.(4)The effects of stiffener and shear-span ratio on shear strength are relatively significant.After the stiffeners are set at the support and the loading point in pairs,the shear strength of the glulam beam increases by 15.05%averagely.With the increase in the shear-span ratio,the shearing strength of the glulam I-beam gradually reduces.The equation of the shearing strength with the shear span ratio is obtained,which is shown by high fitting precision.(5)The shear strength correlation,as proposed by Soltis and Rammer,is suitable not only for rectangular beams,but also for glulam I-beams.

A framework for train derailment risk analysis

This study aims to develop a framework based on the Nadal formula to assess train derailment risk. Monte Carlo simulation was adopted to develop 10000 sets of random parameters to assess train derailment risk subject to the curvature radius of the track, the difference between the flange angle and the equivalent conicity, and accelerations from 250 to 989.22 gal during horizontal earthquake. The results indicated that railway in Taiwan, China has no derailment risk under normal conditions. However, when earthquakes occur, the derailment risk increases with the unloading factor which is caused by seismic force. The results also show that equivalent conicity increases derailment risk;as a result, equivalent conicity should be listed as one of maintenance priorities. In addition, among all train derailment factors, flange angle, equivalent conicity and unload factors are the most significant ones.

Numerical simulation of the seismic behavior of self-centering steel beam-column connections with bottom flange friction devices

A new type of steel moment resisting frame with bottom flange friction devices （BFFDs） has been developed to provide self-centering capacity and energy dissipation, and to reduce permanent deformations under earthquakes. This paper presents a numerical simulation of self-centering beam-column connections with BFFDs, in which the gap opening/closing at the beam-column interfaces is simulated by using pairs of zero-length elements with compression-only material properties, and the energy dissipation due to friction is simulated by using truss elements with specified hysteretic behavior. In particular, the effect of the friction bolt bearing against the slotted plate in the BFFDs was modeled, so that the increase in lateral force and the loss of friction force due to the bolt bearing could be taken into account. Parallel elastic-perfectly plastic gap （ElasticPPGap） materials in the Open System for Earthquake Engineering Simulation （OpenSees） were used with predefined gaps to specify the sequence that each bolt went into the bearing and the corresponding increase in bending stiffness. The MinMax material in OpenSees is used to specify the minimum and maximum values of strains of the ElasticPPGap materials. To consider the loss of friction force due to bok bearing, a number of parallel hysteretic materials were used, and the failure of these materials in sequence simulated the gradual loss of friction force. Analysis results obtained by using the proposed numerical model are discussed and compared with the test results under cyclic loadings and the seismic loading, respectively.

Advanced Analysis of HVDC Electrodes Interference on Neighboring Pipelines

This paper focuses on advanced analysis techniques and design considerations of DC interference generated by HVDC electrodes during normal bipolar and temporary monopolar operations on neighboring metallic utilities, with a special emphasis on buried gas and oil pipelines. This study examines the level of pipeline corrosion, the safety status in the vicinity of exposed appurtenances and the impact of DC interference on the integrity of insulating flanges and impressed current cathodic protection (ICCP) systems. Computation results obtained for different soil models show that different soils can lead to completely different DC interference effects. The results and conclusions presented here can be used as a reference to analyze the severity of DC interference on pipelines due to proximate HVDC electrodes.

Avoiding sealing failure of flanged connection for tubes made of dissimilar materials subjected to elevated temperature

Carbonic composite materials and ceramics appear to be excellent structural materials for parts subjected to very high temperatures in molten salt reactors(MSRs), in which the reactor core outlet temperature is normally above 700℃. Because of the high temperature,there are major challenges in the sealing of flanged connections for tubes made of alloys and nonmetallic materials. In this study, an improved method for sealing bolted flange connections for tubes made of dissimilar materials at high temperature is analyzed. The study focuses on the compensation mechanism for the difference in thermal expansion between the bolts and the flanges. An angle is introduced for the sealing surface in the flanged connection to provide effective sealing. The arctangent of the angle is the ratio of the thickness between the theoretical core of the sealing surface and the outside end face of the flange to the distances between the axis of the flanged joint and the theoretical core of the sealing surface of the flange; the sealing surface of the flange, which is made of the same material as the fastening assemblies, faces the fastening assemblies. To ensure effective sealing, the frictional coefficient between the two sealing surfaces should not exceed the tangent of the angle. This result does not agree well with the solution given by previous researchers. Further, in the modified flanged connection, the compression of each bolt in the clamped condition is increased to maintain the compaction force unchanged without increasing the number of bolts on the flanged joint.

Numerical study on forming complex fitting body on end of integrated stainless steel pipe without welds

It is necessary to use the integrated stainless steel pipe having two fitting bodies without welds while train travelling at high speed. In order to form this type of integrated stainless steel pipe, the method of preforming combined finish forming process is developed. The preforming process is characterized by flaring combined upsetting for left fitting body which is like a flange, and is characterized by tube axial compressive process under die constraint for right fitting body which is like a double-wall pipe. The finite element simulations of the processes are carried out by software package DEFORM, and the results indicate that: 1) left or right fitting body can be formed by a two-step forming process without folding and under-filling defects; 2) by using two-step forming, strain and stress in left fitting body are larger than those in right fitting body, and deformation in right fitting body is more homogenous than the deformation in left fitting body; 3) two or more preforming steps may be needed for left fitting body considering the distributions of strain and stress.

Plastic Deformation Mechanism in Double-Roller Clamping Spinning of Flanged Thin-Walled Cylinder

Double?roller clamping spinning(DRCS) is a new process for forming a thin?walled cylinder with a complex surface flange. The process requires a small spinning force,and can visibly improve forming quality and production e ciency. However,the deformation mechanism of the process has not been completely understood. Therefore,both a finite element numerical simulation and experimental research on the DRCS process are carried out. The results show that both radial force and axial force dominate the forming process of DRCS. The deformation area elongates along the radial direction and bends along the axial direction under the action of the two forces. Both the outer edge and round corner of the flange show the tangential tensile stress and radial compressive stress. The middle region shows tensile tangential stress and radial stress,while the inner edge shows compressive tangential stress and radial stress. Tan?gential tensile strain causes a wall thickness reduction in the outer edge and middle regions of the flange. The large compressive thickness strain causes material accumulation and thus,an increase in the wall thickness of the round corner. Because of bending deformation,the round corner shows a large radial tensile strain in addition. The inner edge of the flange shows small radial compressive strain and tensile strain in thickness. Thus,the wall thickness on the inner edge of the flange continues to increase,although the increment is small. Furthermore,microstructure analysis and tensile test results show that the flanged thin?walled cylinder formed by DRCS has good mechanical properties. The results provide instructions for the application of the DRCS process.