FEM Simulation of a Friction Testing Metliod Based on Combined Forward Conical Can-Backward Straight Can Extrusion

1998 ◽  
Vol 120 (4) ◽  
pp. 716-723 ◽  
Author(s):  
Tamotsu Nakamura ◽  
Niels Bay ◽  
Zhi-Liang Zhang
Keyword(s):  
Friction Coefficient ◽  
Metal Forming ◽  
Fem Simulation ◽  
Fem Analysis ◽  
Rigid Plastic ◽  
Workpiece Material ◽  
Testing Method ◽  
Friction Testing ◽  
Mechanical Press ◽  
The Relationship

A new friction testing method based on combined forward conical can-backward straight can extrusion is proposed in order to evaluate friction characteristics in severe metal forming operations. By this method the friction coefficient along the conical punch surface is determined knowing the friction coefficient along the die wall. The latter is determined by a combined forward and backward can extrusion of straight cans. Calibration curves determining the relationship between punch travel, can heights, and friction coefficient for the two tests are calculated based on a rigid-plastic FEM analysis. Experimental friction tests are carried out in a mechanical press with aluminium alloy A6061 as the workpiece material and different kinds of lubricants. They confirm that the theoretical analysis results in reasonable values for the friction coefficient.

FEM Simulation of Friction Testing Method Based on Combined Forward Rod-Backward Can Extrusion

1997 ◽  
Vol 119 (3) ◽  
pp. 501 ◽  
Author(s):  
Tamotsu Nakamura ◽  
Niels Bay ◽  
Zhi-Liang Zhang
Keyword(s):  
Fem Simulation ◽  
Testing Method ◽  
Friction Testing

Three-Dimensional Rigid-Plastic FEM Simulation of Metal Forming Processes

2006 ◽  
Vol 15 (3) ◽  
pp. 275-279 ◽  
Author(s):  
Young-Suk Kim ◽  
Seung-Han Yang ◽  
Debin Shan ◽  
Seog-Ou Choi ◽  
Sang-Mok Lee ◽  
...  
Keyword(s):  
Metal Forming ◽  
Three Dimensional ◽  
Fem Simulation ◽  
Rigid Plastic

Measurement of Contact Pressure in Metal Forming by Pressure Sensitive Film

1984 ◽  
Vol 106 (2) ◽  
pp. 127-131 ◽  
Author(s):  
K. Mori ◽  
K. Osakada ◽  
M. Fukuda
Keyword(s):  
Contact Pressure ◽  
Metal Forming ◽  
Maximum Pressure ◽  
Rigid Plastic ◽  
Workpiece Material ◽  
Simple Method ◽  
Pressure Sensitive ◽  
Sensitive Film ◽  
Color Density ◽  
Pressure Sensitive Film

A simple method is presented for measuring the distribution of tool contact pressure in metal forming by using a pressure sensitive film which detects the contact pressure from the change in color density. In the method, a sufficiently hard sheet metal compared to the workpiece is inserted between the workpiece and the pressure sensitive film in order to eliminate the influence of frictional shear stress at the tool-workpiece interface on the measured result. Since the maximum pressure which can be determined by the film is 150MPa, lead is used as a workpiece material. Distributions of tool contact pressure are measured in upsetting of cylindrical billets, in free forging of plates of various shapes, and also in backward extrusion of a can. The measured distributions agree well with those computed by the rigid-plastic finite element method.

Estimation of Contact Interface between Tool and Workpiece in Cold Forming Using FEM Analysis

2007 ◽  
Vol 539-543 ◽  
pp. 2275-2280
Author(s):  
Hiroyuki Saiki ◽  
Yasuo Marumo ◽  
Li Qun Ruan ◽  
Junpei Kozasa
Keyword(s):  
Flow Stress ◽  
Friction Coefficient ◽  
Solid Lubricant ◽  
Fem Analysis ◽  
Lubricant Film ◽  
Cold Forging ◽  
Contact Interface ◽  
Rigid Plastic ◽  
Cold Forming ◽  
Minimum Film Thickness

The effect of the flow stress of solid lubricant for cold forging on the tribological conditions was investigated using a rigid-plastic finite element method. The thickness of lubricant film decreases with decreasing flow stress of the solid lubricant and then decreases rapidly. The apparent friction coefficient also decreases with the decrease in the flow stress of the solid lubricant. The thickness of lubricant film tends to decrease with decreasing friction shear factor. When flow stress of solid lubricant is low, the thickness of lubricant film decreases remarkably with increasing tool stroke. We can observe a good correlation between the flow stress of solid lubricant, friction shear factor, minimum film thickness and apparent friction coefficient.

scholarly journals Capabilities of Using Fem in Sheet-Metal Forming

2016 ◽  
Vol 61 (2) ◽  
pp. 947-951
Author(s):  
S. Korga ◽  
A. Duda ◽  
Z. Ciekanowski
Keyword(s):  
Research Methods ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Fem Simulation ◽  
Fem Analysis ◽  
Operating Conditions ◽  
Deformation Analysis ◽  
Plastic Processing ◽  
Metal Deformation

Abstract The aim of this study was to determine and select boundary conditions of modeling and FEM simulation for plastic processing on the example of sheet-metal forming. For sheet-metal deformation analysis, Deform 3D has been used. The study presents research methods for real and virtual conditions. There are also described common features and these differentiating obtained results. Research of conducted process of sheet-metal forming allows to determine the effectiveness of computer research methods. The finite-element method can be used as an effective tool for the study of plastic processing phenomena considering various operating conditions of individual elements provided the appropriate tools for FEM analysis.

Rigid-Plastic FEM Simulation of Orthogonal Cutting Process

2011 ◽  
Vol 338 ◽  
pp. 209-213
Author(s):  
Jiang Xin Zhu ◽  
Jian Xin Deng
Keyword(s):  
Orthogonal Cutting ◽  
Fem Simulation ◽  
Fem Analysis ◽  
Rake Angle ◽  
Cutting Process ◽  
Analysis Model ◽  
Rigid Plastic ◽  
Fem Model ◽  
On Chip ◽  
Chip Separation

This paper presents a rigid-plastic finite element method for orthogonal cutting process by adopting Lagrange method. The rigid-plastic FEM analysis model is established and the rigid-plastic FEM analysis toolkit was developed. Meanwhile, two relevant key problems are discussed systematically, including the rule of chip-workpiece separation and the criterion of tool-chip separation. At last, a simulation example of planing an aluminium alloy (ZL-301) workpiece was conducted. The effects of the cutting stroke, the tool rake angle and the friction coefficient on chip were observed. The numerical simulation results have a good agreement with their experimental ones. It is indicated that the presented FEM model and algorithm are efficient and correct.

A New Type of Controllable Mechanical Press: Motion Control and Experiment Validation

2004 ◽  
Vol 127 (4) ◽  
pp. 731-742 ◽  
Author(s):  
W. Z. Guo ◽  
K. He ◽  
K. Yeung ◽  
R. Du
Keyword(s):  
Motion Control ◽  
Metal Forming ◽  
Variable Speed ◽  
The Press ◽  
Experiment Validation ◽  
Mechanical Press ◽  
New Type ◽  
Key Dimensions ◽  
Angular Displacements ◽  
The Relationship

This paper is the second part of our study on designing a new type of metal forming press. In the first part of the study (Du, R., and Guo, W. Z., 2003, ASME J. Mech. Des., 125(3), pp. 582–592), a new controllable mechanical press is introduced that consists of a large constant-speed motor (CSM) and a small variable-speed servomotor (VSM). The CSM provides up to 80% of the power while the VSM tunes the motion of the ram. This new design has a number of advantages: it is flexible (i.e., its ram motion is programable), fast (its speed is limited only by the mechanical motion), and energy efficient (the CSM can use a large flywheel to ease the large instantaneous metal forming force). This paper focuses on the motion control and experiment validation. First, the inverse kinematics is presented, which gives the relationship between the ram travel and (i) the input angular displacements, velocities, and accelerations of the two motors. Next, a trajectory-planning method is given. Then, the sensitivity analysis is carried out, which helps to determine the key dimensions of the press and the error compensation scheme. Finally, two experiments are shown to demonstrate that the new press can accomplish different tasks.

Simulation and Analysis on the Best Range of Lift-Off Values in MFL Testing

2013 ◽  
Vol 321-324 ◽  
pp. 811-814 ◽  
Author(s):  
De Hui Wu ◽  
Zhong Yuan Zhang ◽  
Zhen Liang Liu ◽  
Xiao Hao Xia
Keyword(s):  
Mechanical Vibration ◽  
Fem Simulation ◽  
Near Surface ◽  
Testing Method ◽  
Surface Areas ◽  
Field Peak ◽  
Lift Off ◽  
Nondestructive Testing Method ◽  
Strength Of Excitation ◽  
Flux Leakage

As a nondestructive testing method, the magnetic flux leakage (MFL) testing technique is widely used for the testing of surface and near-surface areas in ferromagnetic materials. The MFL field is influenced by parameters of defects, strength of excitation, sensor lift-off value and electromagnetic noises etc. A 2-D finite element method (FEM) simulation model is established in this paper to analyze the influence of lift-off values under the condition of mechanical vibration and electromagnetic noises. The distribution of the MFL field peak for different lift-off values and different depth defects is presented. The defect quantization errors caused by the mechanical vibration and electromagnetic noises are introduced to analyze the influence of lift-off values and electromagnetic noises. The best range of lift-off values can be determined from the results of error analysis. It is effective to improve the measuring accuracy in practical MFL testing.

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