Finite element simulations and experimental investigations on ductile fracture in cold forging of aluminum alloy

2018 ◽  
Author(s):  
Amir Amiri ◽  
Amin Nikpour ◽  
Payam Saraeian
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Ductile Fracture ◽  
Finite Element Simulations ◽  
Cold Forging ◽  
Experimental Investigations

scholarly journals A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool Geometry

Materials ◽  
2020 ◽  
Vol 13 (10) ◽  
pp. 2244
Author(s):  
Tae-Wan Ku
Keyword(s):  
Finite Element ◽  
Three Dimensional ◽  
Groove Depth ◽  
Spur Gear ◽  
Finite Element Simulations ◽  
Drive Shaft ◽  
Cold Forging ◽  
Cold Extrusion ◽  
Tool Geometry ◽  
Shoulder Angle

Parametric investigations related to shoulder angle on tool geometry for a combined cold extrusion of a drive shaft, which consisted of spur gear and internal spline structures, were conducted through three-dimensional FE (finite element) simulations. The drive shaft was required to be about 92.00 mm for the face width of the top land on the spur gear part and roughly 22.70 mm for the groove depth of the internal spline section. AISI 1035 carbon steel material with a diameter of 50.00 mm and a length of 121.00 mm was spheroidized and annealed, then used as the initial billet material. A preform as an intermediate workpiece was adopted to avoid the excessive accumulation of plastic deformation during the combined cold extrusion. Accordingly, the cold forging process involves two extrusion operations such as a forward extrusion and a combined extrusion for the preform and the drive shaft. As the main geometric parameters influencing the dimensional quality and the deformed configuration of the final product, the two shoulder angles of θ1 and θ2 for the preform forging and the combined extrusion were both considered to be appropriate at 30°, 45°, and 60°, respectively. Using nine geometric parameter combinations, three-dimensional finite element simulations were performed, and these were used to evaluate the deformed features and the geometric compatibilities on the spur gear structure and the internal spline feature. Based on these comparative evaluations using the numerically simulated results, it is shown that the dimensional requirements of the target shape can be satisfied with the shoulder angle combination of (45°, 45°) for (θ1, θ2).

Formability Predictions of Deep Drawing Process for Aluminum Alloy A1100-O Sheets by Using Combination FEM with ANN

2012 ◽  
Vol 472-475 ◽  
pp. 781-786
Author(s):  
Duc Toan Nguyen ◽  
Young Suk Kim ◽  
Dong Won Jung
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Ductile Fracture ◽  
Deep Drawing ◽  
Fracture Criterion ◽  
Fem Simulation ◽  
Drawing Process ◽  
Ductile Fracture Criterion ◽  
Element Analysis ◽  
Deep Drawing Process

The FEM simulation results of deep drawing process are carried out to create training cases for the artificial neural network (ANN), and then the well-trained ANN(s) is used to predict the formability of aluminum alloy A1100-O sheets. The OYANE’ s ductile fracture criterion equation [J. Mech. Work. Technol. 4 (1980), pp. 65-81] was implemented to predict the formability of deep drawing process. This ductile fracture criterion is introduced and evaluated from the histories of stress and strain calculated by means of finite element analysis in order to get the ductile fracture value (I). The resolution of the results of ductile fracture criterion equations is carried out via a VUMAT user material, using ABAQUS/Explicit finite element code. From the calculative results of FEM simulation with the changing of various parameters, the formability predictions using ANN methodology was investigated by comparing with random case studies of FEM results and shown good agreements

Non-Local Damage Model to Predict the Effect of Pre-Strain on Ductile Fracture in Aluminum Alloy 5052

2012 ◽  
Author(s):  
Yaser Alinaghian ◽  
Mahyar Asadi ◽  
Arnaud Weck
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Finite Element Model ◽  
Ductile Fracture ◽  
Damage Model ◽  
Element Model ◽  
Local Damage ◽  
Micron Size ◽  
Non Local ◽  
The Finite Element Model

Metallic components may develop plastic deformation before in-service loading (pre-strain) due to manufacturing process and/or unexpected loading. This pre-strain not only affects the yield strength of the material but also influences its fracture properties. The work presented here employed laser drilled model materials to better understand the effect of pre-strain on ductile fracture in aluminum alloy 5052. The micron-size laser drilled holes mimic voids forming during ductile fracture. These laser holes are introduced after the material has been pulled in tension to various amounts of pre-strain. The effect of pre-strain on void growth and linkage leading to fracture is studied. A non-local damage is used in a finite element model to predict linkage between voids. This non-local damage has only two adjustable parameters, namely the local failure strain in uniaxial tension and the characteristic length L which intervenes in the non-local averaging scheme. The precise arrangement of the laser holes can be exactly reproduced in the finite element model which allows the model to be validated with the experimental results.

Toughening Mechanisms in Al/Al-SiC Laminated Metal Composites

1996 ◽  
Vol 434 ◽  
Author(s):  
D. R. Lesuer ◽  
J. Wadsworth ◽  
R. A. Riddle ◽  
C. K. Syn ◽  
J. J. Lewandowski ◽  
...  
Keyword(s):  
Fracture Toughness ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Metal Matrix Composite ◽  
Crack Growth ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Volume Fraction ◽  
Finite Element Simulations ◽  
Metal Composites

AbstractThe fracture toughness of laminated metal composites consisting of alternating layers of a metal matrix composite (Al6090/SiC/25p) and a monolithic aluminum alloy (Al5182) has been studied as a function of the volume fraction of the component materials. Finite element simulations of the fracture toughness tests have been used to study the mechanisms of crack growth and extrinsic toughening. The mechanisms responsible for toughening in laminated metal composites are described.

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