Effect of strain rate difference between inside and outside groove in M-K model on prediction of forming limit curve of Ti6Al4V at elevated temperatures

The influence of initial groove angle on strain rate inside and outside groove of Ti6Al4V alloy was investigated.Based on the evolution of strain rate inside and outside groove,the effect of strain rate difference on the evolution of normal stress and effective stress inside and outside groove was also analyzed.The results show that when linear loading path changes from uniaxial tension to equi-biaxial tension,the initial groove angle plays a weaker role in the evolution of strain rate in the M-K model.Due to the constraint of force equilibrium between inside and outside groove,the strain rate difference makes the normal stress inside groove firstly decrease and then increase during calculation,which makes the prediction algorithm of forming limit convergent at elevated temperature.The decrease of normal stress inside groove is mainly caused by high temperature softening effect and the rotation of groove,while the increase of normal stress inside groove is mainly due to strain rate hardening effect.

Simulation of bulk metal forming processes using one-step finite element approach based on deformation theory of plasticity

The bulk metal forming processes were simulated by using a one-step finite element(FE)approach based on deformation theory of plasticity,which enables rapid prediction of final workpiece configurations and stress/strain distributions.This approach was implemented to minimize the approximated plastic potential energy derived from the total plastic work and the equivalent external work in static equilibrium,for incompressibly rigid-plastic materials,by FE calculation based on the extremum work principle.The one-step forward simulations of compression and rolling processes were presented as examples,and the results were compared with those obtained by classical incremental FE simulation to verify the feasibility and validity of the proposed method.

Effects of Heating Rate on the Process Parameters of Superplastic Forming for Zr_(55)Cu_(30)Al_(10)Ni_5

We investigated the effects of heating rate on the process parameters of superplastic forming for Zr55Cu30Al10Ni5 by differential scanning calorimetry. The continuous heating and isothermal annealing analyses suggested that the temperatures of glass transition and onset crystallization are heating rate-dependent in the supercooled liquid region. Then, the time-temperature-transformation diagram under different heating rates indicates that increasing the heating rate can lead to an increase of the incubation time at the same anneal temperature in the supercooled liquid region. Based on the Arrhenius relationship, we discovered that the incubation time increases by 1.08-1.11 times with double increase of the heating rate at the same anneal temperature, and then verified it by the data of literatures and the experimental results. The obtained curve of the max available incubation time reveals that the incubation time at a certain anneal temperature in the supercooled liquid region is not infinite, and will increase with increasing heating rate until this temperature shifts out of the supercooled liquid region because of exceeding critical heating rate. It is concluded that heating rate must be an important processing parameter of superplastic forming for Zr55Cu30Al10Ni5.

A method for calculation of ion distribution in reaction system forming hydroxide

A formula was proposed to calculate the distribution of metal ions quantitatively in chemical reaction system forming hydroxide where precipitation and complex are formed together. The effects of some factors on formation of precipitation and complex were investigated, and the corresponding precipitation rates of zinc, iron （III）, aluminum, copper and magnesium were calculated. As a result, it shows that the proposed formula is reliable. By the proposed formula, the existence state of metal ions in hydroxides reaction system with any metal ions can be well described and the effects of some factors on the distribution of metal ions were determined.

Effects of N Forms and Rates on Vegetable Growth and Nitrate Accumulation

Experiments were carried out on a vegetable field with Peking cabbage(Brassica pekinensis (Lour.) Rupr.), cabbage (Brassica, chinensis var. oleifcra Makino and nemoto),green cabbage (Brassica chinensis L.), spinach (Spinacia oleracea L.) and rape(Brassica campestrisL.) to study the effects of N forms and N rates on their growth and nitrate accumulation. Theresults indicated that application of ammonium chloride, ammonium nitrate, sodium nitrate and ureasignificantly increased the yields and nitrate concentrations of Peking cabbage and spinach.Although no significant difference was found in the yields after application of the 4 N forms,nitrate N increased nitrate accumulation in vegetables much more than ammonium N. The vegetableyields were not increased continuously with N rate increase, and oversupply of N reduced the plantgrowth, leading to a yield decline. This trend was also true for nitrate concentrations in somevegetables and at some sampling times. However, as a whole, the nitrate concentrations in vegetableswere positively correlated with N rates. Thus, addition of N fertilizer to soil was the major causefor increases in nitrate concentrations in vegetables. Nitrate concentrations were much higher inroots, stems and petioles than in blades at any N rate.

A Study on Super Speed Forming of Metal Sheet by Laser Shock Waves

Metal sheet plastic deformation or forming is gener at ed through a mechanical pressure or a thermal variation. These pressure variatio ns or thermal variations can be created by a variety of means such as press form ing, hydroforming, imploding detonation and so on. According to the magnitude of the strain rates all these forming methods can be divided into quasi-static fo rming and dynamical forming. Up to now there are no reports of forming methods w ith the strain rates above 10 5sec -1, even though the exploding forming. In this article, we work on a dynamic super-speed forming method driven by lase r shock waves and advanced a novel concept of laser shock forming. The initial o bservation of the laser shock forming is done through a bugle testing with speci mens of SUS430 sheet metal, using a neodymium-glass laser of pulse energy 10J～ 3 0J and duration of 20 ns (FWHM). The investigation revealed that the plastic de formation during the laser shock forming is characterized as ultrahigh strain ra te up to 10 7sec -1. We indicate that plastic deformation increases nonlin early when the energy density of the laser varies. By investigating the hardness and residual stress of the surfaces, we conclude that laser shock forming is a combination technique of laser shock strengthening and metal forming for introdu cing a strain harden and a compressive residual stress on the surface of the wor k-piece, and the treated surface by laser shock forming has good properties in fatigue and corrosion resistance. This technique can achieve forming wit h or without mould.

Effect of strain rate on microstructure and mechanical properties of spray-formed Al-Cu-Mg alloy

Transmission electron microscopy(TEM),X-ray diffraction(XRD),electron backscattered diffraction(EBSD),and tensile tests were used to study the effects of strain rates(0.1,1 and 9.1 s^(-1))on the microstructure and mechanical properties of spray-formed Al-Cu-Mg alloys during large-strain rolling at 420℃.Results show that during hot rolling,the proportion of high-angle grain boundaries(HAGBs)and the degree of dynamic recrystallization(DRX)initially increase and then decrease,whereas the average grain size and dislocation density show the opposite trend with the increase of the strain rate.In addition,the number of S′phases in the matrix decreases,and the grain boundary precipitates(GBPs)become coarser and more discontinuous as the strain rate increases.When the strain rate increases from 0.1 to 9.1 s^(-1),the tensile strength of the alloy decreases from 492.45 to 427.63 MPa,whereas the elongation initially increases from 12.1%to 21.8%and then decreases to 17.7%.

VISUAL OBSERBATION OF HCFC141b GAS HYDRATE FORMATION/DECOMPOSITION PROCESS OUTSIDE OF A TUBE

In order to design a kind of heat exchanger suitable to the indirect-touched gas hydrate cool storage vessel, a visual observation of HCFC141b gas hydrate formation/decomposition process was presented through a self-designed small-scale visualization apparatus of gas hydrate cool storage. Based on the shooted photos and recorded temperatures, the formation/decomposition process of HCFC141b are described, some characteristics are concluded, and some suggestions of designing heat exchanger are indicated according to the specific characteristics of HCFC141b gas hydrate formation/decomposition process.

Numerical simulation and its application of rheological forming of titanium alloy vane disk

The hot Theological forming method was proposed to form the second titanium alloy vane disk. The hot rheological forming process of the TC11 titanium vane disk under a certain temperature and different strain rates was investigated by using the bulk forming software of DEFORM 3D. A series of results including temperature field, equivalent strain distribution, load-stroke curve and rheology procedure were obtained by this finite element method. The rheological forming characteristics were well realized and the forming parameters were determined. The results and analysis show that with decreasing strain rate, the metal flow more equably and the filling of the vane shape is also better. Moreover, the mechanical properties and microstructures of the products produced by this new technique are improved evidently compared with that produced by traditional method.

Forming Suite在车身同步工程中的应用

建立车身同步工程可以有效地提高产品的可制造性(DFM)、降低产品成本,达到提质增效、提高收益的目的。文章从设计可制造性、成本优化两个方面,通过实例介绍Forming Suite在车身同步工程中的应用,得出基于Forming Suite的车身同步工程不需要专业工艺分析团队,且具有更高同步性的特点的结论。

大截面变化率铝合金异形管整体液力成形工艺设计与优化

目的针对某大截面变化率空心构件成形难的问题,采用液力成形的方法进行成形并对其生产工艺进行优化。方法首先针对目标零件,通过压扁截面处对称及圆截面处对称2种不同的对称方式设计了A型结构和B型结构,通过有限元模拟对比了同一加载路径下2种不同结构的成形特点,选取了成形效果较好的A型结构进行成形工艺研究,建立了A型结构的成形分区图,继而根据成形分区图进行了正交试验设计。结果在同一种加载路径下,A型结构成形的目标零件最大减薄率明显小于B型结构成形的目标零件最大减薄率,且在成形过程中,B型结构压扁特征处易出现褶皱或起皱趋势,而A型结构压扁特征处壁厚分布更加均匀,A型结构成形效果优于B型结构成形效果。优化后的工艺参数如下:压制压力为2 MPa、初始压力为7 MPa、成形压力为15 MPa、轴向进给为13 mm,成形零件最大减薄率为15.9%。结论经成形分区图指导设计的正交成形试验结果均符合设计要求,成形分区图的设立对成形试验的设计具有指导作用;采用优化后的工艺参数获得了较好的试验效果,可为工业生产提供指导。

Microstructure evolution of spray-formed hypereutectic Al-Si alloys in semisolid reheating process

The Al-27%Si alloy was prepared by the spray forming process,and its microstructure evolution during the semisolid reheating process was investigated.The results show that,the primary Si phase coarsens during the reheating process and the coarsening rate increases with the increase of reheating temperature.The eutectic phase is produced in the molten region when quenched in the cold water.The microstructure evolution in the semisolid state can be divided into three stages.The remarkable characteristic of the first stage is only a solid-state phase transformation process.However,the region around the α（Al） matrix gradually melts in the second stage.The primary Si in the liquid phase coarsens obviously,and the eutectic phase is produced in the molten region when the specimens are quenched in cold water.In the last stage,the same thing as that in the second stage happens except that all the α（Al） matrixes are melted.

基于Dynaform的汽车左后侧围外板起皱问题的分析与解决

以某汽车左后侧围外板拉深成形为例,针对制件拉深时出现的严重起皱问题,利用Dynaform非线性有限元软件对制件拉深成形过程进行有限元分析,预测制件起皱趋势。运用UG软件对模具结构、板料尺寸以及拉深筋布置3个方面进行优化,最终制件起皱得到明显改善,最大增厚率由34.3%降至2.5%,符合增厚率<5%的生产要求。

基于RoCoF的构网型变流器惯量阻尼辨识方法

针对当前变流器惯量测试方法较复杂,难以适用于构网型变流器的问题,提出基于频率变化率(RoCoF)的构网型变流器惯量阻尼辨识方法,分析了构网型变流器有功控制的工作机理,推导了构网型变流器有功功率关于电网频率斜坡扰动时的关系式,并依据该关系式阐述了惯量和阻尼辨识步骤。最后,在3.15 MW的构网型电化学储能机组中对所提方法进行了验证,实验结果表明所提方法最大测量误差仅为1.6%,表明了所提方法的有效性和可行性。

Optimizing microstructure and mechanical properties of heat-treated Al-Zn-Mg-Cu alloy by indirect hot deformation technology

In this paper,the indirect thermal tensile experiments of 7075 aluminum alloy including the pre-deformation process at room temperature and the final heat tensile process were carried out,the plastic deformation behavior and forming limit of the material in the compound forming process were investigated considering three pre-deformation amounts 4%,9%,14%,two strain rates 0.001 s^(-1),0.01 s^(-1) and four forming temperatures 300℃,350℃,400℃,450℃.In the indirect hot forming process,the material is sensitive to the pre-deformation,strain rate,and forming temperature,when the strain rate is 0.01 s^(-1),the pre-deformation amount is 4%,and the forming temperature is 400℃,respectively,the maximum tensile deformation is 50 mm.Finally,taking the process in which the forming temperature is 450℃ as an example,according to the observation of the microstructure appearance of fracture,the fracture type in the hot forming process was judged as the ductile fracture.By analyzing the microstructure of the specimen treated with the quenching and artificial aging process,the eutectic T(AlZnMgCu)phase and α(Al)matrix formed a network of non-equilibrium alpha binary eutectic.

Effect of P/M value on the preforms and microstructures of spray formed 70Si30Al alloy

A novel 70Si30Al alloy was prepared by the spray forming process for electronic packaging materials. The effect of the ratio of atomization pressure to metal melt mass flux rate （P/M） on the preforms and microstructures of the spray-deposited 70Si30Al alloy was studied. The results indicate that the PIM value has a considerable influence on the formation of the preforms and the optimal value is in the range of 0.209-0.231 MPa/（kg.min^-1）. The microstructure of the spray formed 70Si30AI alloy is fine and homogenous. The primary silicon phases distributing in the aluminum matrix evenly are fine and irregular. The aluminum matrix is divided into two groups： supersaturated α-Al phase or α-Al phase and Al-Si pseudoeutectic phase or Al-Si eutectic phase.

Improved Correlation for the Volume of Bubble Formed in Air-Water System

In order to address the bubble formation and movement in air-water two-phase flow,single bubble rising in stagnant water is experimentally studied by digital image processing.Bubbles are released individually from the submerged orifices with different diameters(1.81 mm,2.07 mm,2.98 mm,3.92 mm)at different detachment frequency.Images are recorded by a high-speed video camera and processed by digital image processing technique. The factors impacting the formed volume of bubble are discussed.The experimental results showed that a threshold of gas flow rate(400 mm 3 ·s- 1)divides the bubble formation into two regimes:the constant volume regime and the growing volume regime.Especially for the growing volume regime,the surface tension is taken into account.The bubble volume is consisted of two parts:the surface tension impacting part and the gas volume flow rate impacting part.An improved correlation for bubble volume prediction is developed for the two regimes and better coincidence with the experiment data than the previous models is obtained.

Effects of cooling rate on vermicular graphite percentage in a brake drum produced by onestep cored wire injection

In this research, a vermicular graphite cast iron brake drum was produced by cored wire injection in a one-step method. Silica sand and low-density alumina-silicate ceramic were used as molding materials in order to investigate the effect of cooling rate on percentage of vermicular graphite and mechanical properties of the brake drum casting. Several thermocouples were inserted into the casting in the desired positions to measure the temperature change. By means of one-step cored wire injection, the two residual concentrations of Mg and RE were effectively controlled in the ranges of 0.013%-0.017% and 0.019%-0.025%, respectively, which are crucial for the production of vermicular graphite cast iron and the formation of vermicular graphite. In addition, the cooling rate had a significant effect on the vermicular graphite percentage. In the case of the silica mold brake drum casting, there was an obvious difference in the cooling rate with the wall change, leading to a change in vermicular graphite percentage from 70.8% to 90%. In the low-density alumina-silicate ceramic mold casting, no obvious change in temperature was detected by the thermocouples and the percentage of the vermicular graphite was stable at 85%. Therefore, the vermicular graphite cast iron brake drum with a better combination of mechanical properties could be obtained.

Error Estimations, Error Computations, and Convergence Rates in FEM for BVPs

This paper presents derivation of a priori error estimates and convergence rates of finite element processes for boundary value problems (BVPs) described by self adjoint, non-self adjoint, and nonlinear differential operators. A posteriori error estimates are discussed in context with local approximations in higher order scalar product spaces. A posteriori error computational framework (without the knowledge of theoretical solution) is presented for all BVPs regardless of the method of approximation employed in constructing the integral form. This enables computations of local errors as well as the global errors in the computed finite element solutions. The two most significant and essential aspects of the research presented in this paper that enable all of the features described above are: 1) ensuring variational consistency of the integral form(s) resulting from the methods of approximation for self adjoint, non-self adjoint, and nonlinear differential operators and 2) choosing local approximations for the elements of a discretization in a subspace of a higher order scalar product space that is minimally conforming, hence ensuring desired global differentiability of the approximations over the discretizations. It is shown that when the theoretical solution of a BVP is analytic, the a priori error estimate (in the asymptotic range, discussed in a later section of the paper) is independent of the method of approximation or the nature of the differential operator provided the resulting integral form is variationally consistent. Thus, the finite element processes utilizing integral forms based on different methods of approximation but resulting in VC integral forms result in the same a priori error estimate and convergence rate. It is shown that a variationally consistent (VC) integral form has best approximation property in some norm, conversely an integral form with best approximation property in some norm is variationally consistent. That is best approximation property of the integral form and the VC of the integral form is equivalent, one cannot exist without the other, hence can be used interchangeably. Dimensional model problems consisting of diffusion equation, convection-diffusion equation, and Burgers equation described by self adjoint, non-self adjoint, and nonlinear differential operators are considered to present extensive numerical studies using Galerkin method with weak form (GM/WF) and least squares process (LSP) to determine computed convergence rates of various error norms and present comparisons with the theoretical convergence rates.

Electron Exchange Between Oxidized and Reduerd Forms of Ferrocene Derivatives

The rates of electron exchange between oxidized and reduced forms of sev- eral derivatives of ferrocene(1-3)have been measured in acetonitrile by the NMR line h(?)oadening method at 25℃。It was found that the r(?)tes vary with the lengtn of the substitutent chain and the potential of E_(Fe(Ⅲ)/Fe(Ⅱ))in the ferrocene derivatives.