scholarly journals Numerical Simulation for FSW Process at Welding Aluminium Alloy AA6082-T6

Metals ◽  
2019 ◽  
Vol 9 (7) ◽  
pp. 747 ◽  
Author(s):  
Nikola Sibalic ◽  
Milan Vukcevic
Keyword(s):  
Numerical Simulation ◽  
Numerical Simulations ◽  
Large Deformations ◽  
Numerical Data ◽  
Longitudinal Force ◽  
Kinematic Parameters ◽  
Friction Stir ◽  
Numerical Research ◽  
3D Software ◽  
Deform 3D

This paper presents the numerical simulation of the Friction stir welding (FSW) process obtained by using the DEFORM 3D software package. Numerical simulations are based on experimental research, welding of aluminum alloy AA6082-T6 by FSW method, which has the thickness of 7.8 mm. The aim of this paper is to determine the reliability of numerical simulations in the FSW process, which is followed by large deformations, where influential geometric and kinematic parameters are varied. Numerical research was done on the basis of the adopted five-phase orthogonal experimental plan with a variety of factors on two levels and repetition at the central point of the plan for four times. The parameters varied in the experiment are: Welding speed v mm/min, a rotation speed of tool ω rpm, angle of pin slopes α o, a diameter of the pin d mm, diameter of the shoulder D mm. During the performing of the FSW process, forces were measured in three normal directions: Axial force Fz, longitudinal force Fx and side force Fy, as well as the temperature in the adopted measuring positions of the workpiece. The experimental results obtained in this way were compared with the numerical experiment in the same adopted measuring positions, i.e., in the paper an analysis and comparison of the obtained experimental and numerical data of the measured forces and the generated temperature field were made.

Numerical Simulation and Parameter Optimization of Cam’s Fine Blanking Process

2011 ◽  
Vol 396-398 ◽  
pp. 134-139
Author(s):  
An Long ◽  
Rui Ge ◽  
Yi Sheng Zhang ◽  
Li Bo Pan
Keyword(s):  
Numerical Simulation ◽  
Simulation Model ◽  
Parameter Optimization ◽  
Processing Parameters ◽  
Forming Process ◽  
Fine Blanking ◽  
3D Software ◽  
Blanking Process ◽  
Deform 3D

To conclude the mechanics of fine blanking, the numerical simulation model of a cam’s fine blanking process was established, the forming process was simulated by DEFORM-3D software, the deform principle was summarized. Then the effect of three key processing parameters such as gap between punch and die, pressure-pad-force/counter force, serrated ring postion to fine blanking quality were researched, optimized parameters in fine blanking were gained.

Influence of Friction on Metal Flow Behaviour and Die Stress of Backward Extrusion

2011 ◽  
Vol 117-119 ◽  
pp. 1719-1722
Author(s):  
Yong Shun Yang ◽  
Tian Tian Yin ◽  
Ke Feng
Keyword(s):  
Numerical Simulation ◽  
Metal Flow ◽  
Extrusion Process ◽  
Flow Behaviour ◽  
Backward Extrusion ◽  
Die Stress ◽  
3D Software ◽  
Deformation Area ◽  
Deform 3D ◽  
Unit Pressure

In the paper, the Deform-3D software was used to simulate the mechanism of metal flow behaviour under the influence of different friction in the backward extrusion process, and further study its influence on die stress. The numerical simulation demonstrates that: smaller friction could reduce difficult deformation area of extrusion metal significantly; friction state not only affected the plastic deformation extent, but also would increase the consumption of extrusion energy; the unit pressure of punch and stress of inner wall increased along with the increase of friction, meanwhile, the ratio of them increased as well.

scholarly journals A Study on the Performance of Combustion in a HCCI Engine Using n-Heptane by a Multi-Zone Model

2009 ◽  
Author(s):  
Hongsheng Guo ◽  
Hailin Li ◽  
W. Stuart Neill
Keyword(s):  
Numerical Simulation ◽  
Numerical Simulations ◽  
Chemical Species ◽  
Numerical Data ◽  
Operating Conditions ◽  
Zone Model ◽  
Nox Emissions ◽  
Hcci Engine ◽  
Operation Conditions ◽  
Wide Range

A study of n-heptane combustion in an HCCI engine was carried out by a multi-zone numerical simulation that covers a complete engine cycle. A reaction mechanism that includes 177 chemical species and 1638 reactions was used. The results of the numerical simulations were compared to existing experimental data for a range of air/fuel ratios, compression ratios and engine speeds. It is shown that the numerical simulation is able to reasonably capture the experimental cylinder pressure data over a wide range of operation conditions. It also provides a qualitative trend of CO emissions. The numerical simulation overpredicted the combustion at some operating conditions, such as at extremely high air/fuel ratios and higher engine speeds. Some differences were observed between the experimental and numerical data for NOX emissions. The numerical simulation predicted a monotonic decrease in NOX emissions as air/fuel ratio increased or compression ratio decreased, while an increase in NOX emissions was observed experimentally when combustion became very weak at extremely high air/fuel ratios or low compression ratios. It is suggested that further experiments and numerical simulations should be performed to explain this discrepancy.

Numerical Simulation of Equal Channel Angular Pressing for Multi-Pass in Different Routes

2012 ◽  
Vol 268-270 ◽  
pp. 373-377 ◽  
Author(s):  
Xiao Lian Zhao ◽  
Na Chen ◽  
Ning Ning Zhao
Keyword(s):  
Numerical Simulation ◽  
Equal Channel Angular Pressing ◽  
Effective Stress ◽  
Pure Aluminum ◽  
Effective Strain ◽  
Angular Pressing ◽  
3D Software ◽  
Deform 3D

In order to investigate the effect of continued equal channel angular pressing (ECAP) with different routes and passes on the homogeneity of structure, the process of continued ECAP for pure aluminum bar was simulated by DEFORM-3D software. It obtains the load-stroke curves for different passes, distribution of effective stress and effective strain in different routes after the sample is extruded eight passes by ECAP in routes A, BC and C. The results show that the uniformity of the sample is improved with the increase of passes. The microstructure of specimen which is extruded in route BC is the most uniform, but it is the worst in route A.

Friction Stir Lap Joining of Blanks under Different Conditions

2015 ◽  
Vol 651-653 ◽  
pp. 1433-1438 ◽  
Author(s):  
Carlo Bruni ◽  
Alessio D'Orazio ◽  
Mohamad El Mehtedi
Keyword(s):  
Numerical Simulation ◽  
Shear Strength ◽  
Numerical Simulations ◽  
Welded Joints ◽  
Rotational Velocity ◽  
Tool Geometry ◽  
Tensile Shear Strength ◽  
Trial And Error ◽  
Tensile Shear ◽  
Friction Stir

The present investigation aims at studying the effect of the tool geometry and of rotational velocity of the tool, at different welding velocities, on the tensile shear strength of the friction stir welded joints realised with blanks of different thicknesses. The proposed trial and error methodology was based on experiments, numerical simulations and microstructure observations.It was observed that, at the lowest rotational velocity, the slender tool determines tensile shear strength values lower than those obtained with the thick tool in particular at the highest welding velocity investigated. The numerical simulation evidenced a wider stirred zone for the thick tool when compared with that realised with the slender tool at the lowest rotational velocity. Microstructure observations evidenced that the increase in the welding velocity determines reduced stirred zones and an homogenisation of material particularly relevant for the slender tool.

Numerical Simulation for Cold Extrusion of Bevel Gear

2012 ◽  
Vol 497 ◽  
pp. 356-364
Author(s):  
Qing Hua Yang ◽  
Jun Pan ◽  
Jun Xiong Zhang ◽  
Wen Biao Chen ◽  
Bin Meng
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Bevel Gear ◽  
Basic Knowledge ◽  
Cold Extrusion ◽  
Forming Process ◽  
Load Curve ◽  
Extrusion Forming ◽  
3D Software ◽  
Deform 3D

A three-layers assembled cavity die and its technological measures were designed for cold extrusion forming for the bevel gear. Numerical simulation of the cold extrusion forming process was applied using Deform-3D software, load curve, velocity field, stress field and temperature field were analyzed, thus obtain the basic knowledge of the law of the bevel gear deformation. Subsequent targets for optimization were introduced, aiming to solve the remaining problems of the current cold extrusion forming. The accomplished work shows some significance in guiding how to design a die and its technological measures.

Investigation on Free-Wheel Hub for Starter Rotary Forming Process and Die Design Based on Numerical Simulation

2012 ◽  
Vol 557-559 ◽  
pp. 2155-2158
Author(s):  
Ping Wang ◽  
Liang Li
Keyword(s):  
Numerical Simulation ◽  
Hydraulic Press ◽  
Die Design ◽  
Quality Requirement ◽  
Forming Process ◽  
Forming Technology ◽  
Die Structure ◽  
Similar Part ◽  
3D Software ◽  
Deform 3D

Free-wheel hub plays an important role in automobile starter system, so there is higher quality requirement on geometry and precision. In order to improve the efficiency and comprehensive functions of the part, according to the features of the lower part with involute small module internal helical spline, the rotary forming technology was put forward, and the forming process was simulated by the DEFORM-3D software. In the die design, the use of rotary punch made the process of rotary forming achieved in common hydraulic press, and can serve as an important reference to the design of forming process and die structure of similar part.

The Pilot Study on the Defect Prediction and Numerical Simulation in the Superplastic/ Extrusion of Copper Alloy

2007 ◽  
Vol 551-552 ◽  
pp. 293-296
Author(s):  
F.X. Chen ◽  
He Jun Li ◽  
J.Q. Guo ◽  
X.Z. Liu
Keyword(s):  
Numerical Simulation ◽  
Pilot Study ◽  
Strain Rate ◽  
Copper Alloy ◽  
Preventive Measure ◽  
Defect Prediction ◽  
Deformation Defect ◽  
3D Software ◽  
Deform 3D

The aim of the study on the deformation defect is to prevent defects and to improve the quality and to control the deformation. It is important that the preventive measure could be established to advance the scientificity of the product and processing design. In this paper, the reasons of the outer defects such as cracks are analyzed based on the superplasticity of the copper alloy and the process of solid cages in the superplastic extrusion. The prediction and numerical simulation of these typical defects are also carried out using the Deform-3D software grounded on the model of the rigid-visco plastic FEM. The position, time of crack appearance and relation between the strain rate and the defects are also studied. The simulated results are in equivalent agreement with the experiment.

A Numerical Simulation of Microstructure Evolution of GH4169 Alloy Blade during Finish Forging

2011 ◽  
Vol 704-705 ◽  
pp. 113-118
Author(s):  
G. X. Qi ◽  
Rui Bin Mei ◽  
F Wang ◽  
L Bao
Keyword(s):  
Numerical Simulation ◽  
Grain Size ◽  
Microstructure Evolution ◽  
Equivalent Strain ◽  
Average Grain Size ◽  
Back Edge ◽  
3D Software ◽  
Deform 3D ◽  
Gh4169 Alloy ◽  
Good Agreement

In order to predict the microstructure evolution and grain size of GH4169 alloy blade in finish forging process and optimize the parameters, a coupled simulation between thermal mechanical and microstructure evolution was realized through embedding the developed user subroutines into the DEFORM-3D software. The temperature, equivalent strain, dynamic recrystallization fraction, average grain size and grain size distribution were predicted and discussed. The experimental results of microstructure under the same forging condition were investigated. The average grain degree in the blade rabbet and body are 8 and 10 respectively. The calculated results of microstructure have a good agreement with the measured value from experimental data and the prediction error of average grain size is less than 6.7%. The developed program is reliable and the accuracy is satisfying. The distribution of grain size along the blade body is decreased from the middle to the leading and back edge. The shape and microstructure after finish forging under the condition of technology parameters meet the user’s requirement. Keywords: Blade, GH4169 alloy, Numerical simulation, Microstructure, Forging

The Numerical Simulation of Decarburization of 60Si2CrVA in Heat Treatment by DEFORM-3D and the Research of Practical Application

2011 ◽  
Vol 189-193 ◽  
pp. 4207-4211 ◽  
Author(s):  
Liang Gang Dai ◽  
Rong Fa Chen ◽  
Xian Liang Zhang ◽  
Rui Zhu ◽  
Tao Liu ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Heat Treatment ◽  
Process Parameters ◽  
Spring Steel ◽  
Practical Application ◽  
Practical Guide ◽  
Simulation Results ◽  
3D Software ◽  
Deform 3D

In according to the DEFORM-3D software, we simulated the decarburization depth of the 60Si2CrVA spring steel in heat treatment, optimized the process parameters with the simulation results. The result of the research illustrated that the actual decarburization depth is consistent with the simulation result, which demonstrate DEFORM-3D has a practical guide for the process of heat treatment.

Sign in / Sign up

Export Citation Format

Share Document