scholarly journals An Efficient and General Finite Element Model for Double-Sided Incremental Forming

2016 ◽  
Vol 138 (9) ◽  
Author(s):  
Newell Moser ◽  
David Pritchet ◽  
Huaqing Ren ◽  
Kornel F. Ehmann ◽  
Jian Cao
Keyword(s):  
Finite Element ◽  
Incremental Forming ◽  
Mesh Size ◽  
Element Model ◽  
Explicit Finite Element ◽  
Fully Integrated ◽  
Shell Elements ◽  
Mass Scaling ◽  
Element Simulation ◽  
Element Type

Double-sided incremental forming (DSIF) is a subcategory of general incremental sheet forming (ISF), and uses tools above and below a sheet of metal to squeeze and bend the material into freeform geometries. Due to the relatively slow nature of the DSIF process and the necessity to capture through-thickness mechanics, typical finite element simulations require weeks or even months to finish. In this study, an explicit finite element simulation framework was developed in LS-DYNA using fully integrated shell elements in an effort to lower the typical simulation time while still capturing the mechanics of DSIF. The tool speed, mesh size, element type, and amount of mass scaling were each varied in order to achieve a fast simulation with minimal sacrifice regarding accuracy. Using 8 CPUs, the finalized DSIF model simulated a funnel toolpath in just one day. Experimental strains, forces, and overall geometry were used to verify the simulation. While the simulation forces tended to be high, the trends were still well captured by the simulation model. The thickness and in-plane strains were found to be in good agreement with the experiments.

Finite Element Modeling of Unidirectional Non-Crimp Fabric for Manufacturing of Composites with Embedded Cabling

2013 ◽  
Vol 554-557 ◽  
pp. 484-491 ◽  
Author(s):  
Alexander S. Petrov ◽  
James A. Sherwood ◽  
Konstantine A. Fetfatsidis ◽  
Cynthia J. Mitchell
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
Explicit Finite Element ◽  
Shell Elements ◽  
Beam Elements ◽  
Hybrid Finite Element ◽  
International Benchmarking ◽  
Unidirectional Glass ◽  
Forming Simulations

A hybrid finite element discrete mesoscopic approach is used to model the forming of composite parts using a unidirectional glass prepreg non-crimp fabric (NCF). The tensile behavior of the fabric is represented using 1-D beam elements, and the shearing behavior is captured using 2-D shell elements into an ABAQUS/Explicit finite element model via a user-defined material subroutine. The forming of a hemisphere is simulated using a finite element model of the fabric, and the results are compared to a thermostamped part as a demonstration of the capabilities of the used methodology. Forming simulations using a double-dome geometry, which has been used in an international benchmarking program, were then performed with the validated finite element model to explore the ability of the unidirectional fabric to accommodate the presence of interlaminate cabling.

Finite Element Simulation of Ultrasonic Incremental Forming

2016 ◽  
Vol 836-837 ◽  
pp. 452-461
Author(s):  
P.Y. Li ◽  
Qiang Liu ◽  
Wu Run An ◽  
Shu Juan Li
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Axial Force ◽  
Vibration Frequency ◽  
Incremental Forming ◽  
Single Point ◽  
Element Model ◽  
Single Point Incremental Forming ◽  
Element Simulation ◽  
Law Of Cosines

This paper briefly describes the principle of the ultrasonic single point incremental forming of the sheet metal. In which we established the finite element model and finished the finite simulation with ABAQUS. According to the simulation result, we analyzed the influence law of vibration frequency of the axis on the distribution of the stress and strain of the sheet metal, the thickness, and the axial force in the process of ultrasonic single point incremental forming of the sheet metal. The result shows that the influence on the stress and thickness of the sheet metal is minimal, and the influence on the strain follows the law of cosines in which the strain is minimum when the vibration frequency is equal to 15kHZ.The influence on the axial force is that when the frequency is f=0kHz～40kHz the axial force decreases with the increase of the frequency. However, the axial force increased dramatically with the increase of the frequency when the frequency is above 40kHz.

Characterization and Finite Element Modeling of Unidirectional Non-Crimp Fabric for Composite Manufacturing

2012 ◽  
Vol 504-506 ◽  
pp. 225-230 ◽  
Author(s):  
Alexander Petrov ◽  
James A. Sherwood ◽  
Konstantine A. Fetfatsidis
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
Explicit Finite Element ◽  
Shell Elements ◽  
Beam Elements ◽  
Hybrid Finite Element ◽  
International Benchmarking ◽  
Characterization Test ◽  
Shear Frame

A hybrid finite element discrete mesoscopic approach is proposed to model the forming of composite parts using a unidirectional glass prepreg non-crimp fabric (NCF). The tensile behavior of the fabric is represented using 1-D beam elements, and the shearing behavior is captured using 2-D shell elements. The material is characterized using tensile and shear frame tests. These properties are then incorporated into an ABAQUS/Explicit finite element model via user-defined material subroutines. The shear frame characterization test is simulated using a finite element model of the fabric, and the finite element results are compared to experimental data as a validation of the methodology. The thermostamping of a double-dome geometry, which has been used in an international benchmarking program, is modeled as a demonstration of the capabilities of the proposed methodology.

Application of Mass Scaling Technology in Steel Tube Rolling by Finite Element Simulation

2014 ◽  
Vol 887-888 ◽  
pp. 1139-1142
Author(s):  
Ning Pang ◽  
Zhi Yi Zhao
Keyword(s):  
Finite Element ◽  
Rolling Force ◽  
Element Model ◽  
Rolling Process ◽  
Steel Tube ◽  
Scaling Factor ◽  
Tube Rolling ◽  
Mass Scaling ◽  
Element Simulation ◽  
Operation Platform

Based on Abaqus/Explicit operation platform, a finite element model of Yantai Baosteel Φ460mm PQF mill was established to study the mass scaling factors influence of the rolling process. The experimental results show that mass scaling factor has smaller impact on the temperature. Distortion of rolling force and Mises stress gradually occurs with the increase of mass scaling factor. Under the premise of ensuring the calculation accuracy, a best mass scaling factor is found to improve the computational efficiency of the model.

Finite Element Simulation of Tire-Rim Interface

1989 ◽  
Vol 17 (4) ◽  
pp. 305-325 ◽  
Author(s):  
N. T. Tseng ◽  
R. G. Pelle ◽  
J. P. Chang
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Finite Element Simulation ◽  
Contact Pressure ◽  
Element Model ◽  
Experimental Measurements ◽  
Inflation Pressure ◽  
Interference Fit ◽  
Element Simulation ◽  
Rubber Composite

Abstract A finite element model was developed to simulate the tire-rim interface. Elastomers were modeled by nonlinear incompressible elements, whereas plies were simulated by cord-rubber composite elements. Gap elements were used to simulate the opening between tire and rim at zero inflation pressure. This opening closed when the inflation pressure was increased gradually. The predicted distribution of contact pressure at the tire-rim interface agreed very well with the available experimental measurements. Several variations of the tire-rim interference fit were analyzed.

Redrawing Operation a Star Shape from Cylindrical Shape Using Experimental and FE Analysis

2020 ◽  
Vol 38 (1A) ◽  
pp. 25-32
Author(s):  
Waleed Kh. Jawad ◽  
Ali T. Ikal
Keyword(s):  
Finite Element ◽  
Effective Strain ◽  
Element Model ◽  
Cylindrical Shape ◽  
Element Analysis ◽  
Punch Force ◽  
Maximum Value ◽  
Element Simulation ◽  
Blank Sheet ◽  
The Finite Element Model

The aim of this paper is to design and fabricate a star die and a cylindrical die to produce a star shape by redrawing the cylindrical shape and comparing it to the conventional method of producing a star cup drawn from the circular blank sheet using experimental (EXP) and finite element simulation (FES). The redrawing and drawing process was done to produce a star cup with the dimension of (41.5 × 34.69mm), and (30 mm). The finite element model is performed via mechanical APDL ANSYS18.0 to modulate the redrawing and drawing operation. The results of finite element analysis were compared with the experimental results and it is found that the maximum punch force (39.12KN) recorded with the production of a star shape drawn from the circular blank sheet when comparing the punch force (32.33 KN) recorded when redrawing the cylindrical shape into a star shape. This is due to the exposure of the cup produced drawn from the blank to the highest tensile stress. The highest value of the effective stress (709MPa) and effective strain (0.751) recorded with the star shape drawn from a circular blank sheet. The maximum value of lamination (8.707%) is recorded at the cup curling (the concave area) with the first method compared to the maximum value of lamination (5.822%) recorded at the cup curling (the concave area) with the second method because of this exposure to the highest concentration of stresses. The best distribution of thickness, strains, and stresses when producing a star shape by

3D Finite Element Simulation for Turning of Hardened 45 Steel

2019 ◽  
Vol 13 (2) ◽  
pp. 181-188
Author(s):  
Meng Liu ◽  
Guohe Li ◽  
Xueli Zhao ◽  
Xiaole Qi ◽  
Shanshan Zhao
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Force ◽  
Finite Element Simulation ◽  
Orthogonal Experiment ◽  
Element Model ◽  
3D Finite Element ◽  
Element Simulation ◽  
Metal Machining ◽  
Single Factor Experiment

Background: Finite element simulation has become an important method for the mechanism research of metal machining in recent years. Objective: To study the cutting mechanism of hardened 45 steel (45HRC), and improve the processing efficiency and quality. Methods: A 3D oblique finite element model of traditional turning of hardened 45 steel based on ABAQUS was established in this paper. The feasibility of the finite element model was verified by experiment, and the influence of cutting parameters on cutting force was predicted by single factor experiment and orthogonal experiment based on simulation. Finally, the empirical formula of cutting force was fitted by MATLAB. Besides, a lot of patents on 3D finite element simulation for metal machining were studied. Results: The results show that the 3D oblique finite element model can predict three direction cutting force, the 3D chip shape, and other variables of metal machining and the prediction errors of three direction cutting force are 5%, 9.02%, and 8.56%. The results of single factor experiment and orthogonal experiment are in good agreement with similar research, which shows that the model can meet the needs for engineering application. Besides, the empirical formula and the prediction results of cutting force are helpful for the parameters optimization and tool design. Conclusion: A 3D oblique finite element model of traditional turning of hardened 45 steel is established, based on ABAQUS, and the validation is carried out by comparing with experiment.

Finite Element Analysis of the ESTELA M1 Airplane Firewall (Representative Specimen)

2011 ◽  
Author(s):  
V. Ramirez-Elias ◽  
E. Ledesma-Orozco ◽  
H. Hernandez-Moreno
Keyword(s):  
Finite Element ◽  
Federal Aviation Administration ◽  
Element Model ◽  
Maximum Load ◽  
Load Factor ◽  
Representative Specimen ◽  
Maximum Displacement ◽  
Element Analysis ◽  
Element Simulation ◽  
The Relationship

This paper shows the finite element simulation of a representative specimen from the firewall section in the AEROMARMI ESTELA M1 aircraft. This specimen is manufactured in glass and carbon / epoxy laminates. The specimen is subjected to a load which direction and magnitude are determined by a previous dynamic loads study [10], taking into account the maximum load factor allowed by the FAA (Federal Aviation Administration) for utilitarian aircrafts [11]. A representative specimen is manufactured with the same features of the firewall. Meanwhile a fix is built in order to introduce the load directions on the representative specimen. The relationship between load and displacement is plotted for this representative specimen, whence the maximum displacement at the specific load is obtained, afterwards it is compared with the finite element model, which is modified in its laminate thicknesses in order to decrease the deviation error; subsequently this features could be applied to perform the whole firewall analysis in a future model [10].

Numerical Simulation of Microstructure Evolution in AZ31 Magnesium Alloy during Equal Channel Angular Pressing

2014 ◽  
Vol 609-610 ◽  
pp. 495-499
Author(s):  
Guo Cheng Ren ◽  
Xiao Juan Lin ◽  
Shu Bo Xu
Keyword(s):  
Finite Element ◽  
Magnesium Alloy ◽  
Equal Channel Angular Pressing ◽  
Microstructure Evolution ◽  
Element Model ◽  
Az31 Magnesium Alloy ◽  
Angular Pressing ◽  
Ecap Process ◽  
Element Simulation ◽  
3D Software

The microstructure and material properties of AZ31 magnesium alloy are very sensitive to process parameters, which directly determine the service properties. To explore and understand the deformation behavior and the optimization of the deformation process, the microstructure evolution during equal channel angular pressing was predicted by using the DEFORM-3D software package at different temperature. To verify the finite element simulation results, the microstructure across the transverse direction of the billet was measured. The results show that the effects strain and deformation temperatures on the microstructure evolution of AZ31 magnesium during ECAP process are significant, and a good agreement between the predicted and experimental results was obtained, which confirmed that the derived dynamic recrystallization mathematical models can be successfully incorporated into the finite element model to predict the microstructure evolution of ECAP process for AZ31 magnesium.

A pragmatic approach for the evaluation of depth-sensing indentation in the self-similar regime

2021 ◽  
pp. 1-24
Author(s):  
Hamidreza Mahdavi ◽  
Konstantinos Poulios ◽  
Christian F. Niordson
Keyword(s):  
Finite Element ◽  
Element Model ◽  
Depth Sensing ◽  
Finite Element Software ◽  
Element Simulation ◽  
Unique Material ◽  
Reverse Analysis ◽  
Supplementary Material ◽  
Two Parameters ◽  
Force Displacement

Abstract This work evaluates and revisits elements from the depth-sensing indentation literature by means of carefully chosen practical indentation cases, simulated numerically and compared to experiments. The aim is to close a series of debated subjects, which constitute major sources of inaccuracies in the evaluation of depth-sensing indentation data in practice. Firstly, own examples and references from the literature are presented in order to demonstrate how crucial self-similarity detection and blunting distance compensation are, for establishing a rigorous link between experiments and simple sharp-indenter models. Moreover, it is demonstrated, once again, in terms of clear and practical examples, that no more than two parameters are necessary to achieve an excellent match between a sharp indenter finite element simulation and experimental force-displacement data. The clear conclusion is that reverse analysis methods promising to deliver a set of three unique material parameters from depth-sensing indentation cannot be reliable. Lastly, in light of the broad availability of modern finite element software, we also suggest to avoid the rigid indenter approximation, as it is shown to lead to unnecessary inaccuracies. All conclusions from the critical literature review performed lead to a new semi-analytical reverse analysis method, based on available dimensionless functions from the literature and a calibration against case specific finite element simulations. Implementations of the finite element model employed are released as supplementary material, for two major finite element software packages.

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