Forming of Al 5182-O in a Servo Press at Room and Elevated Temperatures

2015 ◽  
Vol 137 (5) ◽  
Author(s):  
Long Ju ◽  
Shrinivas Patil ◽  
Jim Dykeman ◽  
Taylan Altan
Keyword(s):  
Finite Element ◽  
Deep Drawing ◽  
Elevated Temperatures ◽  
Cost Effective ◽  
Element Model ◽  
Material Behavior ◽  
Bulge Test ◽  
Element Analysis ◽  
Automotive Manufacturing ◽  
Servo Press

Aluminum alloys are increasingly used in automotive manufacturing to save weight. The drawability of Al 5182-O has been proven at room temperature (RT) and it is also shown that formability is further enhanced at elevated temperatures (ETs) in the range of 250–350 °C. A cost effective application of ET forming of Al alloys can be achieved using heated blank and cold dies (HB–CD). In this study, the material behavior of Al 5182-O is characterized using tensile test and viscous bulge test at RT. The nonisothermal finite element model (FEM) of deep drawing is developed using the commercial software pamstamp. Initially, deep drawing simulations and tests were carried out at RT using a 300 ton servo press, with a hydraulic cushion. The predictions with flow stress curves obtained from tensile and bulge tests were compared with experimental data. The effect of punch speed and temperature rise during forming at RT is investigated. The warm forming simulations were carried out by combining material data at ETs obtained from the literature. The coupled effects of sheet temperatures and punch speeds are investigated through the finite element analysis (FEA) to provide guidelines for ET stamping of Al 5182-O.

An Improved Control Arm Design for a Commercial Vehicle

2021 ◽  
Author(s):  
Sinan Yıldırım ◽  
Ufuk Çoban ◽  
Mehmet Çevik
Keyword(s):  
Finite Element ◽  
Cost Effective ◽  
Element Model ◽  
Tensile Tests ◽  
The Body ◽  
Von Mises Stress ◽  
Driving Safety ◽  
Design Development ◽  
Element Analysis ◽  
Von Mises

Suspension linkages are one of the fundamental structural elements in each vehicle since they connect the wheel carriers i.e. axles to the body of the vehicle. Moreover, the characteristics of suspension linkages within a suspension system can directly affect driving safety, comfort and economics. Beyond these, all these design criteria are bounded to the package space of the vehicle. In last decades, suspension linkages have been focused on in terms of design development and cost reduction. In this study, a control arm of a diesel public bus was taken into account in order to get the most cost-effective design while improving the strength within specified boundary conditions. Due to the change of the supplier, the control arm of a rigid axle was redesigned to find an economical and more durable solution. The new design was analyzed first by the finite element analysis software Ansys and the finite element model of the control arm was validated by physical tensile tests. The outputs of the study demonstrate that the new design geometry reduces the maximum Von Mises stress 15% while being within the elastic region of the material in use and having found an economical solution in terms of supplier’s criteria.

Finite Element Modeling of Biodegradable Stents

2013 ◽  
Author(s):  
Nic Debusschere ◽  
Matthieu De Beule ◽  
Peter Dubruel ◽  
Patrick Segers ◽  
Benedict Verhegghe
Keyword(s):  
Finite Element ◽  
Mechanical Behavior ◽  
Mechanical Performance ◽  
Cost Effective ◽  
Minimal Invasive ◽  
Material Behavior ◽  
Element Analysis ◽  
Design And Optimization ◽  
Stent Restenosis ◽  
Biodegradable Stents

Biodegradable stents, which temporarily support a stenotic blood vessel and afterwards fully disappear, have recently gained a lot of interest. They avoid long-term complications associated with conventional stents such as late stent thrombosis and in-stent restenosis. Moreover, degradable stents allow for a restoration of vasomotion and vessel growth which makes them particularly suitable for pediatric applications [1]. Finite element simulations have proven to be an efficient and cost-effective tool to investigate and optimize the mechanical performance of minimal invasive devices such as stents [2]. Biodegradable stents have however created new challenges in their design and optimization via finite element analysis because of their complex time-varying material behavior. To correctly simulate the mechanical behavior of biodegradable stents, a model should be developed that incorporates the effect of degradation upon all material characteristics. By combining existing constitutive material models based on continuum damage theory we were able to create such a virtual environment in which the transitional mechanical behavior of biodegradable stents can be investigated.

Finite Element Analysis of Flange Joint With Single and Twin Gaskets Under External Bending Load

2015 ◽  
Author(s):  
N. Rino Nelson ◽  
N. Siva Prasad ◽  
A. S. Sekhar
Keyword(s):  
Finite Element ◽  
Work Performance ◽  
Elevated Temperatures ◽  
Bending Moment ◽  
Element Model ◽  
Pressure Vessels ◽  
Flange Joint ◽  
Element Analysis ◽  
Bending Load ◽  
Gasket Material

Gasketed flange joint is a vital component in pressure vessels and piping systems. Flange joint is usually subjected to bending load due to expansion, wind load, self-weight, etc. Most of the flange design methods use equivalent pressure to include the effect of external bending loads. It becomes complex when the joint is subjected to bending load at elevated temperatures, due to the nonlinear behavior of gasket material. In the present work, performance of the flange joint has been studied under external bending load at elevated temperatures. A 3D finite element model is developed, considering the nonlinearities in the joint due to gasket material and contact between its members along with their temperature dependent material properties. The performance of the joint under different bolt preloads, internal fluid pressures and temperatures is studied. Flange joint with two gaskets (twin gasketed joint) placed beside each other radially, is also analyzed under external bending moment. The maximum allowable bending moments at different internal temperatures, for single and twin gasketed joints with spiral wound gasket are arrived.

scholarly journals Technological and Theoretical Application of Finite Element Modeling of Deep Drawing

2018 ◽  
Vol 9 (1) ◽  
pp. 51-54
Author(s):  
Ádám Bertók ◽  
Viktor Gonda ◽  
Károly Széll
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Finite Element Model ◽  
Deep Drawing ◽  
Metal Forming ◽  
Element Model ◽  
Stress And Strain ◽  
Element Analysis ◽  
Forming Technology ◽  
Theoretical Application

Abstract For metal forming problems, even for a simple forming technology, finite element analysis can provide a solution for calculating deformations, determining stress and strain distributions. The aim of this study is to create a parametric finite element model for deep drawing technology, by which technological optimization as well as theoretical problems can be solved. By performing parameter studies, numerous cases can be analyzed.

CFD and Thermo-Mechanical Analysis for Heat Exchanger Used in Aero Engine

2008 ◽  
Author(s):  
Ho Seung Jeong ◽  
Jong Rae Cho ◽  
Lae Sung Kim ◽  
Man Yeong Ha ◽  
Ji Hwan Jeong ◽  
...  
Keyword(s):  
Finite Element ◽  
Heat Exchanger ◽  
Elevated Temperatures ◽  
High Strength ◽  
Element Model ◽  
Mechanical Analysis ◽  
Cfd Analysis ◽  
Element Analysis ◽  
Alloy 625 ◽  
Heat Exchanger Design

The multi-physics analysis using both the CFD and thermo-mechanical analysis is carried out to estimate the life of the heat exchanger which is operated under the conditions of high temperature and high pressure. First CFD analysis is carried out to obtain the distribution of flow, pressure and temperature around heat exchanger. The distribution of pressure, temperature and heat transfer coefficient obtained from the CFD analysis is transferred to the thermo-mechanical analysis using finite element analysis technique and is used as data to calculate the mechanical and thermal stress distribution in the heat exchanger. For the CFD analysis, it is considered a segment of heat exchangers using the symmetric and periodic conditions. For the thermo-mechanical analysis, the present finite element model considered both a segment and a half of full geometry by using the symmetric and periodic conditions. Alloy 625 is used for the present heat exchanger design due to its high strength at the elevated temperatures. The temperature-dependent physical properties of Alloy 625 for the thermo-mechanical analysis are used in a temperature ranges of 300∼1100K. Fatigue analysis is performed using a Goodman-diagram to assess the life of the present heat exchanger.

Computer Simulation of Deep Drawing Process for a Laminated Composite Cup

2007 ◽  
Author(s):  
Tushar Naik ◽  
Zhong Hu
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Deep Drawing ◽  
Laminated Composites ◽  
Laminated Composite ◽  
Element Model ◽  
Drawing Process ◽  
Forming Process ◽  
Element Analysis ◽  
Deep Drawing Process

The anisotropic nature of laminated composites creates a unique opportunity and also a great challenge for tailoring their behavior during the forming processes according to the design requirements. In this work, design and simulation of a deep drawing process for fiber-reinforced laminated composites were conducted by using finite element analysis. The effects of the fiber orientation and stacking order on the deep drawing process were investigated based on the basic understanding of forming process of the isotropic aluminum alloy (Al-1100) and laminated composite material (Grilon RVZ-15H nylon/glass). A three dimensional finite element model incorporating layered structural laminates with various fiber orientations was developed. The load-stroke relationship, changes in thickness, and stress-strain distribution were investigated and compared for both aluminum alloy and laminated composites of [0]12, [0/90]6 and [0/90/45/135]3, which can be employed for detailed design and process optimization.

Cost-Effective Method of Optimization of Stacking Sequences in the Cylindrical Composite Shells Using Genetic Algorithm

2020 ◽  
Author(s):  
Ehsan Daneshkhah ◽  
Reza Jafari Nedoushan ◽  
Davoud Shahgholian ◽  
Nima Sina
Keyword(s):  
Genetic Algorithm ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Experimental Tests ◽  
Cost Effective ◽  
Element Model ◽  
External Pressure ◽  
Element Analysis ◽  
Cost Effective Method ◽  
Critical Buckling Pressure

Buckling is one of the common destructive phenomena, which occurs in composite cylinders subjected to external pressure. In this paper, different methods to optimize stacking sequence of these cylinders are investigated. A finite element model is proposed in order to predict critical buckling pressure and the results are validated with previous experimental data. Theoretical analysis based on NASA SP‐8007 solution and the simplified equation for cylinder buckling of ASME RD-1172 are presented and discussed. The results of theoretical and finite element analysis and experimental tests are compared for both glass and carbon epoxy cylinders. Using NASA and ASME formulations, optimal laminations of cylinders in order to maximize buckling pressure, are obtained by genetic algorithm method. Suggested laminations and the values of corresponding critical buckling pressure calculated by finite element analysis, are presented and compared in various states. Obtained results show that while predicted buckling loads of finite element analysis are reliable, NASA formulation can be used in a very cost-effective method to optimize the buckling problems.

Numerical and Experimental Investigations on the Warm Deep Drawing of DP Steel Tailor-Welded Blanks

2013 ◽  
Vol 763 ◽  
pp. 179-183
Author(s):  
Zhi Fu Cao ◽  
Zhi Feng Chen ◽  
Wei Chen ◽  
Qing Zhao ◽  
Yang Zhang ◽  
...  
Keyword(s):  
Finite Element ◽  
Deep Drawing ◽  
Elevated Temperatures ◽  
Experimental Investigations ◽  
Element Analysis ◽  
Dp Steel ◽  
Punch Force ◽  
Tailor Welded Blanks ◽  
Warm Deep Drawing ◽  
Increasing Temperature

The warm forming technology is applied to improve the dual phase (DP) steel tailor-welded blanks (TWBs) forming properties. In this paper, the warm deep drawing of DP590 steel TWBs was studied by both the experimental approach and the finite element analysis. The results indicated that the formability of the DP steel TWBs could be reduced slightly at lower temperatures and improved significantly at elevated temperatures. The reasonable punch force and blank holder force decrease rapidly as increasing temperature. Finite element analyses were performed to predict the formability of the warm deep drawing of DP590 steel TWBs and to investigate the rules of the warm deep drawing. The numerical simulation results are in good agreement with experimental results.

КОНСТРУКТИВНО-ТЕХНОЛОГІЧНІ ОСОБЛИВОСТІ ХВОСТО-ВИХ БАЛОК СІТЧАСТОГО ТИПУ З ПОЛІМЕРНИХ КОМПО-ЗИЦІЙНИХ МАТЕРІАЛІВ ВЕРТОЛЬОТІВ ТРАНСПОРТНОЇ КАТЕГОРІЇ

2020 ◽  
pp. 15-30
Author(s):  
А. Г. Гребеников ◽  
И. В. Малков ◽  
В. А. Урбанович ◽  
Н. И. Москаленко ◽  
Д. С. Колодийчик
Keyword(s):  
Finite Element ◽  
Strain State ◽  
Layer Structure ◽  
Metal Structure ◽  
Element Model ◽  
Stress Strain ◽  
Element Analysis ◽  
Mesh Structure ◽  
Stress Strain State ◽  
Mesh Structures

The analysis of the design and technological features of the tail boom (ТB) of a helicopter made of polymer composite materials (PCM) is carried out.Three structural and technological concepts are distinguished - semi-monocoque (reinforced metal structure), monocoque (three-layer structure) and mesh-type structure. The high weight and economic efficiency of mesh structures is shown, which allows them to be used in aerospace engineering. The physicomechanical characteristics of the network structures are estimated and their uniqueness is shown. The use of mesh structures can reduce the weight of the product by a factor of two or more.The stress-strain state (SSS) of the proposed tail boom design is determined. The analysis of methods for calculating the characteristics of the total SSS of conical mesh shells is carried out. The design of the tail boom is presented, the design diagram of the tail boom of the transport category rotorcraft is developed. A finite element model was created using the Siemens NX 7.5 system. The calculation of the stress-strain state (SSS) of the HC of the helicopter was carried out on the basis of the developed structural scheme using the Advanced Simulation module of the Siemens NX 7.5 system. The main zones of probable fatigue failure of tail booms are determined. Finite Element Analysis (FEA) provides a theoretical basis for design decisions.Shown is the effect of the type of technological process selected for the production of the tail boom on the strength of the HB structure. The stability of the characteristics of the PCM tail boom largely depends on the extent to which its design is suitable for the use of mechanized and automated production processes.A method for the manufacture of a helicopter tail boom from PCM by the automated winding method is proposed. A variant of computer modeling of the tail boom of a mesh structure made of PCM is shown.The automated winding technology can be recommended for implementation in the design of the composite tail boom of the Mi-2 and Mi-8 helicopters.

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