Nonlinear Finite Element Analysis of Spring-Back Characteristics in the Cold-Forming Process of Three-Dimensionally Curved Thick Metal Plates

2013 ◽  
Vol 135 (3) ◽  
Author(s):  
Jeom Kee Paik ◽  
Jeong Hwan Kim ◽  
Bong Ju Kim ◽  
Chang Hyo Tak
Keyword(s):  
Finite Element ◽  
Three Dimensional ◽  
Steel Plates ◽  
Research Centre ◽  
Spring Back ◽  
Forming Process ◽  
Element Analysis ◽  
Cold Forming ◽  
Metal Plates ◽  
National University

The present paper is part of the study to develop the advanced computer aided manufacture (CAM) system called the changeable die system (CDS) that applies the cold-forming technique to produce curved thick metal plates with complex, three-dimensional geometry [Paik et al., 2009, “Development of the Changeable Die System for the Cold-Forming of Three-Dimensionally Curved Metal Plates,” The Lloyd's Register Educational Trust Research Centre of Excellence, Pusan National University, Korea]. This paper focuses on the procedure of predicting the spring-back characteristics using elastic-plastic large deflection finite element method, which is a key technical element within the framework of the CDS process. The validity of the procedure is confirmed by comparison with experimental results obtained by the CDS machine in the cold-forming process of curved steel plates.

Analysis of Spring-Back Behavior in the Cold-Forming Process of Three-Dimensionally Curved Metal Plates

2010 ◽  
Author(s):  
Jeom Kee Paik ◽  
Jeong Hwan Kim ◽  
Bong Ju Kim ◽  
Chang Hyo Tak
Keyword(s):  
Three Dimensional ◽  
Nonlinear Finite Element ◽  
Steel Plates ◽  
Nonlinear Finite Element Method ◽  
Spring Back ◽  
Forming Process ◽  
Cold Forming ◽  
Metal Plates ◽  
Computer Aided ◽  
Advanced Computer

The present paper is part of the study to develop the advanced computer aided manufacture (CAM) system called the changeable die system (CDS) that applies the cold-forming technique to produce curved metal plates with complex, three-dimensional geometry. This paper focuses on the algorithm of predicting the spring-back behavior using nonlinear finite element method, which is a key element within the framework of the CDS process. The validity of the algorithm is confirmed by comparison with experimental results obtained by the CDS machine in the cold-forming process of curved steel plates.

Three Dimensional Finite Element Analysis of Staggered Backward Flow Forming Process

2013 ◽  
Author(s):  
Hemant Shinde ◽  
Pushkar Mahajan ◽  
Ramesh Singh ◽  
K. Narasimhan
Keyword(s):  
Finite Element ◽  
Three Dimensional ◽  
Process Conditions ◽  
State Variables ◽  
Forming Process ◽  
Flow Forming ◽  
Element Analysis ◽  
Cold Forming ◽  
Cylindrical Workpiece ◽  
Backward Flow Forming

Flow forming is one of the cold forming processes which is mainly used to produce thin-walled high-precision tubular components. A three dimensional coupled-field thermo-mechanical finite element model for staggered three-roller backward flow forming of a cylindrical workpiece of MDN-250 maraging steel has been developed using Abaqus/Explicit. In this model, the effect of tip radius of the rollers and friction between the rollers and the workpiece has been considered. The bottom of the workpiece is fixed in the axial direction so that diametral reduction and the axial elongation can be studied. Simulations have been carried out at different process conditions to study the state variables, such as stresses and strains obtained during the deformation. The model has been benchmarked with the experimental results for thickness reduction and the error in the thickness prediction is limited to 4%. The roll forces have been benchmarked against analytical formulation and a difference of 13–20% has been observed. The effect of flow forming process variables, such as feed rate and reduction ratio on the stress/strain distribution and roll forces have been studied. The results show that the roll forces increase at higher feed rates and higher reduction ratios whereas the equivalent strains increase at lower feed rates and higher reduction ratios. In addition, a parametric study has been conducted to study ovality, diametral growth, roll forces, stresses and strains as a function of process parameters.

Concurrent Engineering Design of Sheet Stamping by Using an Inverse FE Approach

1997 ◽  
Author(s):  
Shiyong Yang ◽  
Kikuo Nezu
Keyword(s):  
Finite Element ◽  
Concurrent Engineering ◽  
Process Simulation ◽  
Three Dimensional ◽  
Sheet Forming ◽  
Design Stage ◽  
Forming Process ◽  
Element Analysis ◽  
Preliminary Design Stage ◽  
Product And Process

Abstract An inverse finite element (FE) algorithm is proposed for sheet forming process simulation. With the inverse finite element analysis (FEA) program developed, a new method for concurrent engineering (CE) design for sheet metal forming product and process is proposed. After the product geometry is defined by using parametric patches, the input models for process simulation can be created without the necessity to define the initial blank and the geometry of tools, thus simplifying the design process and facilitating the designer to look into the formability and quality of the product being designed at preliminary design stage. With resort to a commercially available software, P3/PATRAN, arbitrarily three-dimensional product can be designed for manufacturability for sheet forming process by following the procedures given.

Numerical and experimental analysis on cold-forming and spring-back of hull plate

2018 ◽  
Vol 233 (3) ◽  
pp. 561-569 ◽  
Author(s):  
Wei Shen ◽  
Renjun Yan ◽  
Shuangying Li
Keyword(s):  
Three Dimensional ◽  
Dimensional Accuracy ◽  
Ship Hull ◽  
Laser Forming ◽  
Successive Approximation Method ◽  
Spring Back ◽  
Forming Process ◽  
Cold Forming ◽  
Thick Plates ◽  
Forming Mechanism

Ship hull structures are fabricated by curved thick plates before they are welded together. There are traditional methods such as, line heating and laser-forming methods for plate bending. However, it is recognized that the hot-forming technology causes a series of troubles on doubly or multiple curved plates. Multi-point forming mechanism with square press heads is a new forming process for three-dimensional ship hull plate. Cold-forming has a high dimensional accuracy but results in spring-back. The spring-back process of curved thick plates in the finite element method is analyzed and the predicted results are compared with the test results in the present paper. To ensure the forming precision, the successive approximation method is also developed and verified to control the spring-back.

Three-Dimensional Elastic-Plastic Finite-Element Analysis of the Flattening of Wire Between Plain Rolls*

2000 ◽  
Vol 123 (3) ◽  
pp. 397-404 ◽  
Author(s):  
H. Utsunomiya ◽  
P. Hartley ◽  
I. Pillinger
Keyword(s):  
Finite Element ◽  
Elastic Recovery ◽  
Three Dimensional ◽  
Lateral Spread ◽  
Radius Of Curvature ◽  
Forming Process ◽  
Empirical Formulas ◽  
Element Analysis ◽  
Finite Element Program ◽  
Elastic Plastic

It is normal industrial practice to roll round edged flat wires from round circular wires using plain rolls. Although this is not a complex type of metal forming process, the internal deformation is highly three-dimensional. It is important to be able to determine the lateral spread, elongation and final profile precisely. In this paper, this process has been analyzed using an elastic-plastic finite element program. Firstly, algorithms for integrating the constitutive equations, i.e., return mapping algorithms, are evaluated to determine the most accurate technique. Then, the influences of friction and reduction in thickness on the deformation characteristics are investigated. The lateral spread and the radius of curvature of the free surface are quantitatively in reasonable agreement with those obtained from empirical formulas. The lateral spread increases with friction and with reduction. The variation of elongation in the roll bite is investigated in detail. It is found that the elongation is not uniformly distributed across the cross section. After passing the roll gap, the distribution is compensated by the elastic recovery of wire, otherwise it may cause edge waves.

Elastic-Plastic Finite Element Simulation of Bulge Forming Process Using a Variable Cross-Section Solid Bulging Mold

2011 ◽  
Vol 189-193 ◽  
pp. 4405-4408
Author(s):  
Ke Wang ◽  
Zhe Ying Wang ◽  
Xing Wei Sun
Keyword(s):  
Finite Element ◽  
Cross Section ◽  
Metal Flow ◽  
Three Dimensional ◽  
Variable Cross Section ◽  
Flow Mode ◽  
Variable Cross ◽  
Forming Process ◽  
Element Analysis ◽  
Screw Rotor

Bulge forming is a novel process aimed at common products including T-branches, cross branches and angle branches. But bulging forming has not applied for two-head abnormity-shaped hollow screw rotor reported in literature. Simulation of the bulging forming of two-head abnormity-shaped hollow screw rotor has not been reported. This paper presents a simulation of the bulge forming process of two-head abnormity-shaped hollow screw rotor using a variable cross-section solid bulging mold. Some conditions including the effect of friction, boundary conditions, contact conditions and the space motion, etc are presented. The mathematical model of three-dimensional finite element analysis has been established. The distribution of generalized plastic strain and general metal flow mode in cross section of two abnormity-shaped hollow screw rotor has been analyzed. It is an effective method for the analysis of other defects and the optimization of process parameters further.

scholarly journals Investigating of Mechanical Behavior of AA5083 in the Pressing Process Using Finite Element Analysis

2017 ◽  
Vol 11 (9) ◽  
pp. 51
Author(s):  
Babak Beglarzadeh ◽  
Behnam Davoodi
Keyword(s):  
Mechanical Properties ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Friction Stress ◽  
Forming Process ◽  
Element Analysis ◽  
Cold Forming ◽  
Aluminum Alloy 5083 ◽  
And Control

The process of cold forming is considered of the most different industries and the use of such process in the manufacture of components and small parts has expanded. Therefore, analyzing the behavior of metals in this process to identify and control durability that is the main factor of limiting process has particular importance in industrial forming processes. In this study, cold forming process of aluminum metal has been studied and its effect on its mechanical properties has been evaluated. For this purpose, first modeling piece of aluminum alloy 5083 for cold forming process is carried out and using finite element analysis, mechanical properties of considered piece during cold forming processes are investigated. The results show that by reducing friction, stress and strain during the process will reduce, thereby durability of the piece increases, or in other words, ductile fracture occurs in longer life and higher stresses. The results show that by proper forming operations, it can be improved the strength and durability of aluminum alloy. Finally, validation of results, by comparing simulation results with experimental results is carried out.

scholarly journals Finite Element Simulation Research on Medium Plate Multi-Pass Welding Temperature Field

2015 ◽  
Vol 9 (1) ◽  
pp. 786-790
Author(s):  
Huawei Liu ◽  
Linxin Niu
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Heat Source ◽  
Steel Plate ◽  
Three Dimensional ◽  
Steel Plates ◽  
Element Analysis ◽  
Welding Temperature ◽  
Welding Arc ◽  
Input Position

V-grooved steel plate 30mm in thickness has been taken into consideration to research on the distribution of temperature field for the multi-pass welding of steel plate with intermediate thickness in the whole process of welding and cooling. With the establishment of a reasonable three-dimensional solid model, the utility of ANSYS software for finite element analysis, the usage of birth-death elements and the setting of normal Gauss heat source, steps have been undertaken to achieve the goal that the process of multi-pass welding about steel plate in intermediate thickness is simulated and the law of distribution about welding temperature field is obtained. The research results indicate the following: the temperature in every point of base metal changes constantly when the steel plate 30mm in thickness is being welded, the heat input position and position behind heat source are the integral parts which have the highest temperature during the process that welded joints are welded, the temperature gradient in front of welding arc is pretty large as well as that behind welding arc is relatively small. The calculation results are consistent with actual observations providing exactly reliable references for stress field of the welding on steel plates.

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