Numerical Simulations and Design of Shearing Process for Aluminum Alloys

2004 ◽  
Vol 127 (3) ◽  
pp. 612-621 ◽  
Author(s):  
Aniruddha Khadke ◽  
Somnath Ghosh ◽  
Ming Li
Keyword(s):  
Aluminum Alloys ◽  
Numerical Simulations ◽  
Process Parameters ◽  
Design Method ◽  
Experimental Studies ◽  
Burr Formation ◽  
Design Parameters ◽  
Arbitrary Lagrangian Eulerian ◽  
Damage Models ◽  
Commercial Code

This work combines experimental studies with finite element simulations to develop a reliable numerical model for the simulation of shearing process in aluminum alloys. The critical concern with respect to product quality in this important process is burr formation. Numerical simulations are aimed at understanding the role of process variables on burr formation and for recommending process design parameters. The commercial code ABAQUS-Explicit with the arbitrary Lagrangian-Eulerian kinematic description is used in this study for numerical simulations. An elastic-plastic constitutive model with experimentally validated damage models are incorporated through the user subroutine VUMAT in ABAQUS, for modeling deformation and ductile fracture in the material. Macroscopic experiments with microscopic observations are conducted to characterize the material and to calibrate the constitutive and damage models. Parametric study is done to probe the effect of process parameters and finally, a genetic algorithm (GA) based design method is used to determine process parameters for minimum burr formation.

Vortex-Induced Vibrations of a Cylinder at Subcritical Reynolds Number

2011 ◽  
Author(s):  
Yoann Jus ◽  
Elisabeth Longatte ◽  
Jean-Camille Chassaing ◽  
Pierre Sagaut
Keyword(s):  
Reynolds Number ◽  
Numerical Simulations ◽  
Numerical Study ◽  
Damping Ratio ◽  
Experimental Studies ◽  
Cross Flow ◽  
Physical Analysis ◽  
Arbitrary Lagrangian Eulerian ◽  
Vortex Induced Vibrations ◽  
Low Mass

The present work focusses on the numerical study of Vortex-Induced Vibrations (VIV) of an elastically mounted cylinder in a cross flow at moderate Reynolds numbers. Low mass-damping experimental studies show that the dynamic behavior of the cylinder exhibits a three-branch response model, depending on the range of the reduced velocity. However, few numerical simulations deal with accurate computations of the VIV amplitudes at the lock-in upper branch of the bifurcation diagram. In this work, the dynamic response of the cylinder is investigated by means of three-dimensional Large Eddy Simulation (LES). An Arbitrary Lagrangian Eulerian framework is employed to account for fluid solid interface boundary motion and grid deformation. Numerous numerical simulations are performed at a Reynolds number of 3900 for both no damping and low-mass damping ratio and various reduced velocities. A detailed physical analysis is conducted to show how the present methodology is able to capture the different VIV responses.

Statistical Analysis of Process Parameters in Drilling of Al/Al2O3p Metal Matrix Composites

2014 ◽  
Vol 14 (3) ◽  
pp. 171-175 ◽  
Author(s):  
Yashvir Singh ◽  
Amneesh Singla ◽  
Ajay Kumar
Keyword(s):  
Surface Roughness ◽  
Statistical Analysis ◽  
Process Parameters ◽  
Metal Matrix ◽  
Design Method ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Signal To Noise ◽  
Drilling Parameters

AbstractThis paper presents a statistical analysis of process parameters for surface roughness in drilling of Al/Al2O3p metal matrix composite. The experimental studies were conducted under varying spindle speed, feed rate, point angle of drill. The settings of drilling parameters were determined by using Taguchi experimental design method. The level of importance of the drilling parameters is determined by using analysis of variance. The optimum drilling parameter combination was obtained by using the analysis of signal-to-noise ratio. Through statistical analysis of response variables and signal-to-noise ratios, the determined significant factors are depth of cut and drill point angle with the contributions of 87% and 12% respectively, whereas the cutting speed is insignificant contributing by 1% only. Confirmation tests verified that the selected optimal combination of process parameter through Taguchi design was able to achieve desired surface roughness.

Enabling Variation of Manufacturing Process Parameters in Early Stages of Product Development

2006 ◽  
Author(s):  
Patrik Boart ◽  
Ola Isaksson
Keyword(s):  
Product Development ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Mechanical Design ◽  
Design Method ◽  
Local Level ◽  
Simulation Models ◽  
Design Parameters ◽  
Functional Requirements ◽  
Early Stages

Currently, mechanical design of aero engine structural components is defined by dimensioning of Design Parameters (DP's) to meet Functional Requirements (FR's). FR's are typically loads, geometrical interfaces and other boundary conditions. Parameters from downstream processes are seldom actually seen as DP's. This paper proposes that downstream process parameters are treated as DP's which calls for engineering methods that can define and evaluate these extended set of DP's. Using the proposed approach manufacturing process alternatives can be used as DP's in early stages of product development. Both the capability to quantitatively assess impact of varying manufacturing DP's, and the availability of these design methods are needed to succeed as an early phase design method. One bottleneck is the preparation time to define and generate these advanced simulation models. This paper presents how these manufacturing process simulations can be made available by automating the weld simulation preparation stages of the engineering work. The approach is based on a modular approach where the methods are defined with knowledge based engineering techniques-operating close to the CAD system. Each method can be reused and used independently of each other and adopted to new geometries. A key advantage is the extended applicability to new products, which comes with a new set of DP's. On a local level the lead time to generate such manufacturing simulation models is reduced with more than 99% allowing manufacturing process alternatives to be used as DP's in early stages of product development.

Robust Optimization for Tube Bending Process Based on Finite Element Method

2012 ◽  
Vol 531-532 ◽  
pp. 746-750
Author(s):  
Xue Wen Chen ◽  
Ze Hu Liu ◽  
Jing Li Zhang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Robust Design ◽  
Process Parameters ◽  
Design Method ◽  
Design Parameters ◽  
Tube Bending ◽  
Performance Variation ◽  
Bending Process ◽  
Element Method

The main causes of performance variation in tube bending process are variations in the mechanical properties of material, initial tube thickness, coefficient of friction and other forming process parameters. In order to control this performance variation and to optimize the tube bending process parameters, a robust design method is proposed in this paper for the tube bending process, based on the finite element method and the Taguchi method. During the robust design process, the finite element analysis is incorporated to simulate the tube bending process and calculate the objective function value, the orthogonal design method is selected to arrange the simulation experiments and calculate the S/N ratio. Finally, a case study for the tube bending process is implemented. With the objective to control tube crack (reduce the maximum thinning ratio) and its variation, the robust design mathematical model is established. The optimal design parameters are obtained and the maximum thinning ratio has been reduced and its variation has been controlled.

A Computational and Experimental Study of Cold Rolling of Aluminum Alloys With Edge Cracking

2004 ◽  
Vol 126 (1) ◽  
pp. 74-82 ◽  
Author(s):  
S. Ghosh ◽  
M. Li ◽  
D. Gardiner
Keyword(s):  
Finite Element ◽  
Aluminum Alloys ◽  
Cold Rolling ◽  
Experimental Studies ◽  
Rolling Process ◽  
Rolled Strip ◽  
Damage Models ◽  
Friction Laws ◽  
Model Predictions ◽  
Edge Cracking

This paper identifies various modeling issues that are necessary for successful simulation of the cold rolling process by comparing it with experiments on aluminum alloys. It combines considerable experimental studies with finite element simulations using the ABAQUS/Explicit commercial finite element code to identify and evaluate modeling parameters, such as the material properties and friction laws. Damage models are incorporated in the numerical simulations by using plasticity with damage variables e.g., the Gurson-Tvergaard model with evolving porosity and Cockcroft-Latham with damage in terms of plastic work. The 3D model predictions are compared with predictions from 2D models to understand the limitations of 2D simulations in predicting the stresses, strains and evolving damage in the rolled strip.

Experimental studies on friction stir welding of aluminium alloy 5083 and prediction of temperature distribution using arbitrary Lagrangian–Eulerian-based finite element method

2021 ◽  
pp. 146442072110681
Author(s):  
R Pramod ◽  
Vikram Kumar S Jain ◽  
S Mohan Kumar ◽  
B Girinath ◽  
A Rajesh Kannan ◽  
...  
Keyword(s):  
Finite Element ◽  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Experimental Studies ◽  
Welding Process ◽  
Element Model ◽  
Arbitrary Lagrangian Eulerian ◽  
Friction Stir ◽  
Friction Stir Welding Process

The present work focused on welding aluminium alloy 5083 using the friction stir welding process. Suitable welding process parameters were identified to fabricate a defect-free butt joint with a tool rotational speed of 1600 rpm, traverse speed of 20 mm/min and tilt angle of 3°. The microstructure at the nugget zone, thermo mechanically affected zone, heat-affected zone and base metal zone are examined. Mechanical properties of the weldment exhibited promising results with an average joint efficiency and hardness of 75.70% and 94.0 ± 5.0 vickers hardness, respectively. Fractography revealed ductile mode of failure in base and weld metal tensile samples. Furthermore, a 3D thermomechanical finite element model was utilized to simulate the friction stir welding process using the selected process parameters. Arbitrary Lagrangian–Eulerian-based model aided in predicting residual stress distributions and thermal history during the friction stir welding process.

A Consistent Implementation of Inelastic Material Models into Steady State Rolling

2016 ◽  
Vol 44 (3) ◽  
pp. 174-190 ◽  
Author(s):  
Mario A. Garcia ◽  
Michael Kaliske ◽  
Jin Wang ◽  
Grama Bhashyam
Keyword(s):  
Steady State ◽  
Numerical Simulations ◽  
Viscoelastic Material ◽  
Rolling Contact ◽  
Arbitrary Lagrangian Eulerian ◽  
Ale Formulation ◽  
Inelastic Material ◽  
Material Formulation ◽  
Steady State Rolling ◽  
Efficient Alternative

ABSTRACT Rolling contact is an important aspect in tire design, and reliable numerical simulations are required in order to improve the tire layout, performance, and safety. This includes the consideration of as many significant characteristics of the materials as possible. An example is found in the nonlinear and inelastic properties of the rubber compounds. For numerical simulations of tires, steady state rolling is an efficient alternative to standard transient analyses, and this work makes use of an Arbitrary Lagrangian Eulerian (ALE) formulation for the computation of the inertia contribution. Since the reference configuration is neither attached to the material nor fixed in space, handling history variables of inelastic materials becomes a complex task. A standard viscoelastic material approach is implemented. In the inelastic steady state rolling case, one location in the cross-section depends on all material locations on its circumferential ring. A consistent linearization is formulated taking into account the contribution of all finite elements connected in the hoop direction. As an outcome of this approach, the number of nonzero values in the general stiffness matrix increases, producing a more populated matrix that has to be solved. This implementation is done in the commercial finite element code ANSYS. Numerical results confirm the reliability and capabilities of the linearization for the steady state viscoelastic material formulation. A discussion on the results obtained, important remarks, and an outlook on further research conclude this work.

EXPERIMENTAL STUDIES OF REINFORCED CONCRETE STRUCTURES WITH CROSS-SHAPED SPATIAL CRACK UNDER TORSION WITH BENDING

2020 ◽  
Vol 92 (6) ◽  
pp. 13-25
Author(s):  
Vl.I. KOLCHUNOV ◽  
◽  
A.I. DEMYANOV ◽  
M.M. MIHAILOV ◽  
◽  
...  
Keyword(s):  
Reinforced Concrete ◽  
Experimental Determination ◽  
Calculation Method ◽  
Experimental Studies ◽  
Concrete Structures ◽  
Design Parameters ◽  
Reinforced Concrete Structures ◽  
Experimental Scheme

The article offers a method and program for experimental studies of reinforced concrete structures with cross-shaped spatial crack under torsion with bending, the main purpose of which is to check the design assumptions and experimental determination of the design parameters of the proposed calculation method. The conducted experimental studies provide an opportunity to test the proposed calculation apparatus and clarify the regularities for determining deflections, angles of rotation of extreme sections, and stresses in the compressed zone of concrete. For analysis, the article presents a typical experimental scheme for the formation and development of cracks in the form of a sweep, as well as characteristic graphs of the dependence of the angles of rotation of end sections.

scholarly journals A modular design method based on TRIZ and AD and its application to cutter changing robot

2021 ◽  
Vol 13 (7) ◽  
pp. 168781402110343
Author(s):  
Mei Yang ◽  
Yimin Xia ◽  
Lianhui Jia ◽  
Dujuan Wang ◽  
Zhiyong Ji
Keyword(s):  
Modular Design ◽  
Design Method ◽  
Idea Generation ◽  
Design Parameters ◽  
Problem Analysis ◽  
Concept Design ◽  
Functional Requirements ◽  
Shield Tunneling ◽  
Structural Hierarchy ◽  
And Performance

Modular design, Axiomatic design (AD) and Theory of inventive problem solving (TRIZ) have been increasingly popularized in concept design of modern mechanical product. Each method has their own advantages and drawbacks. The benefit of modular design is reducing the product design period, and AD has the capability of problem analysis, while TRIZ’s expertise is innovative idea generation. According to the complementarity of these three approaches, an innovative and systematic methodology is proposed to design big complex mechanical system. Firstly, the module partition is executed based on scenario decomposition. Then, the behavior attributes of modules are listed to find the design contradiction, including motion form, spatial constraints, and performance requirements. TRIZ tools are employed to deal with the contradictions between behavior attributes. The decomposition and mapping of functional requirements and design parameters are carried out to construct the structural hierarchy of each module. Then, modules are integrated considering the connections between each other. Finally, the operation steps in application scenario are designed in temporal and spatial dimensions. Design of cutter changing robot for shield tunneling machine is taken as an example to validate the feasibility and effectiveness of the proposed method.

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