Finite Element Simulation of Flexible Roll Forming with Supplemented Material Data and the Experimental Verification

Flexible roll forming is a promising manufacturing method for the production of variable cross section products. Considering the large plastic strain in this forming process which is much larger than that of uniform deformation phase of uniaxial tensile test, the widely adopted method of simulating the forming processes with non-supplemented material data from uniaxial tensile test will certainly lead to large error. To reduce this error, the material data is supplemented based on three constitutive models. Then a finite element model of a six passes flexible roll forming process is established based on the supplemented material data and the original material data from the uniaxial tensile test. The flexible roll forming experiment of a B pillar reinforcing plate is carried out to verify the proposed method. Final cross section shapes of the experimental and the simulated results are compared. It is shown that the simulation calculated with supplemented material data based on Swift model agrees well with the experimental results, while the simulation based on original material data could not predict the actual deformation accurately. The results indicate that this material supplement method is reliable and indispensible, and the simulation model can well reflect the real metal forming process. Detailed analysis of the distribution and history of plastic strain at different positions are performed. A new material data supplement method is proposed to tackle the problem which is ignored in other roll forming simulations, and thus the forming process simulation accuracy can be greatly improved.

A Study of Dynamic Analysis Method for the Rigid-Flexible Coupled Bar Linkage System

In order to present a dynamic analysis method for the rigid-flexible coupled bar linkage system(RFCBLS),the flexible element motion equation was gotten by Lagrange Equation and the rigid element motion equation was gotten based on rigid constraint conditions.The multi-body system(MBS) is a complex mechanism and its components have quite different rigidities.If it is considered as a rigid MBS(RMBS) to do its dynamic analysis,elastic deformation's ignorance will lead to inaccurate analysis.If it is considered as a flexible MBS(FMBS) to establish,analyze,and solve the model,quite large system equations make it difficult to solve.The better method is as follows:the complex mechanism system is regarded as a rigid-flexible coupled system(RFCS) to make dynamic characteristic of rigid components be equivalent,system equation is established by FMBS' way,and system equation dimensions are reduced by transition matrices' introduction.A dynamic analysis method for rigid element and flexible element coupling was presented based on the FMBS.The analyzed crank slide-block mechanism results show that the dynamic analysis method for RFCBLS is quick and convenient.

Power flow transmission in a coupled flexible system with active executive elements

Based on its prototype of machine-isolator-foundation systems, a theoretical model for dynamic coupled linear system is established, in which both the passive and active control factors are considered. Power flow is used as the cost function to evaluate the isolation effectiveness. And the transmission of vibratory power flow from a vibrating rigid body into a simply supported thin panel through passive isolators and actuators is investigated numerically. The active control strategy is summarized in the conclusion.

Topology optimization of support structure of telescope skin based on bit-matrix representation NSGA-II

Non-dominated sorting genetic algorithm II（NSGA-II）with multiple constraints handling is employed for multi-objective optimization of the topological structure of telescope skin,in which a bit-matrix is used as the representation of a chromosome,and genetic algorithm（GA）operators are introduced based on the matrix.Objectives including mass,in-plane performance,and out-of-plane load-bearing ability of the individuals are obtained by fnite element analysis（FEA）using ANSYS,and the matrix-based optimization algorithm is realized in MATLAB by handling multiple constraints such as structural connectivity and in-plane strain requirements.Feasible confgurations of the support structure are achieved.The results confrm that the matrix-based NSGA-II with multiple constraints handling provides an effective method for two-dimensional multi-objective topology optimization.