This document summarizes recent simulations of cold forming processes using the DEFORMTM-3D software. It describes three case studies: 1) the coining of a heat sink with self-contacting surfaces, 2) the assembly of a nut and plate with mesh-to-mesh contact, and 3) the extrusion of a helical gear using rotational symmetry. It also discusses simulations of thread rolling and stress analysis of the threading dies. The case studies demonstrate capabilities for modeling multiple deforming objects, self-contact, and large rotational problems. Finite element simulation has become an integral part of process design in metal forming industries.
Prediction of Draw Ratio in Deep Drawing through Software Simulationsirjes
Deep drawing process is one of the most commonly used Metal Forming Process within the
industrial field. Different analytical, numerical, empirical and experimental methods have been developed in
order to analyze it. In this paper deep drawing process with varying punch and die geometries are analysed. This
work reports on the stages of finite element analysis (FEA) and simulations of a Deep drawing process. The
obtained result allows to find optimum draw ratios in deep drawing.
Simulation of Deep-Drawing Process of Large Panelstheijes
The article deals with the analysis of formability of deep-drawing DC06 steel sheets. The aim of the investigations is to verify possibilities of formability of sheet metal with thickness of 0.85 mm. The mechanical parameters of the sheets have been determined in uniaxial tensile and bulge tests. The numerical simulations using AUTOFORM has been carried out for two drawpiece models. Obtained results can be used during the simulation of real forming process.
This presentation is useful; for understanding the processes of rapid prototyping and its application.
Also this presentation includes the STL file format and problems with STL files.
Experimental Validation of 3-D Printed BoltsIJMERJOURNAL
ABSTRACT: 3-D printing, which is an automated production process with layer-by-layer control, has been gaining rapid development in recent years. 3-D printing is the process by which a 3-D digital design is converted into a component by depositing material using additive processing. Three dimensional (3D) printing offers versatile possibilities for adapting the structural parameters on engineering scaffolds. These three dimensional elements were produced from Poly Lactic Acid (PLA) and Acrylonitrile butadiene Styrene (ABS)by means of fused deposition process. This work is initiated by designing a three dimensional model of an ISO standard bolt and creating a 3D printing of this model using PLA and ABS as material. Designing will be carried out using SOLIDWORKS. Later on the design is analysed on analysis software (ANSYS) for deformation, equivalent stress and shear stress. A prototype model of this bolt will be created using three dimensional printer. Shear test is performed using UTM on the bolts that are created using three dimensional printer. Each bolt material’s failure forces are noted down and shear stresses are calculated. The PLA and ABS bolts are compared with each other. They are also checked for safe limits by comparing them with their respective material properties.
Investigation of Process Parameters for Optimization of Surface Roughness in ...IJERA Editor
Surface roughness has significant effect on functionality and service life of components. If surface roughness is properly controlled then, performance of the component enhances in operational applications. Surface roughness becomes key concern when intricate profiles and shapes are required to be manufactured in components. The objective of the paper is to bring up an adequate surface roughness in finish cut by optimizing process variables. If initial surface form is obtained by proper control of machining parameters then additional finishing efforts and lead time reduce a lot. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of process parameters is essential in order to arrest surface roughness and thereby improve surface textures. Experimental investigations are performed to study the effect of pulse current, pulse on time and gap voltage on response of surface roughness, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining
Prediction of Draw Ratio in Deep Drawing through Software Simulationsirjes
Deep drawing process is one of the most commonly used Metal Forming Process within the
industrial field. Different analytical, numerical, empirical and experimental methods have been developed in
order to analyze it. In this paper deep drawing process with varying punch and die geometries are analysed. This
work reports on the stages of finite element analysis (FEA) and simulations of a Deep drawing process. The
obtained result allows to find optimum draw ratios in deep drawing.
Simulation of Deep-Drawing Process of Large Panelstheijes
The article deals with the analysis of formability of deep-drawing DC06 steel sheets. The aim of the investigations is to verify possibilities of formability of sheet metal with thickness of 0.85 mm. The mechanical parameters of the sheets have been determined in uniaxial tensile and bulge tests. The numerical simulations using AUTOFORM has been carried out for two drawpiece models. Obtained results can be used during the simulation of real forming process.
This presentation is useful; for understanding the processes of rapid prototyping and its application.
Also this presentation includes the STL file format and problems with STL files.
Experimental Validation of 3-D Printed BoltsIJMERJOURNAL
ABSTRACT: 3-D printing, which is an automated production process with layer-by-layer control, has been gaining rapid development in recent years. 3-D printing is the process by which a 3-D digital design is converted into a component by depositing material using additive processing. Three dimensional (3D) printing offers versatile possibilities for adapting the structural parameters on engineering scaffolds. These three dimensional elements were produced from Poly Lactic Acid (PLA) and Acrylonitrile butadiene Styrene (ABS)by means of fused deposition process. This work is initiated by designing a three dimensional model of an ISO standard bolt and creating a 3D printing of this model using PLA and ABS as material. Designing will be carried out using SOLIDWORKS. Later on the design is analysed on analysis software (ANSYS) for deformation, equivalent stress and shear stress. A prototype model of this bolt will be created using three dimensional printer. Shear test is performed using UTM on the bolts that are created using three dimensional printer. Each bolt material’s failure forces are noted down and shear stresses are calculated. The PLA and ABS bolts are compared with each other. They are also checked for safe limits by comparing them with their respective material properties.
Investigation of Process Parameters for Optimization of Surface Roughness in ...IJERA Editor
Surface roughness has significant effect on functionality and service life of components. If surface roughness is properly controlled then, performance of the component enhances in operational applications. Surface roughness becomes key concern when intricate profiles and shapes are required to be manufactured in components. The objective of the paper is to bring up an adequate surface roughness in finish cut by optimizing process variables. If initial surface form is obtained by proper control of machining parameters then additional finishing efforts and lead time reduce a lot. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of process parameters is essential in order to arrest surface roughness and thereby improve surface textures. Experimental investigations are performed to study the effect of pulse current, pulse on time and gap voltage on response of surface roughness, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity
Linking design and manufacturing on a PLM platformiosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Integrating parametric design with robotic additive manufacturing for 3D clay...Antonio Arcadu
ABSTRACT This paper presents an ongoing work in relation to the development of a parametric design algorithm and an automated system for additive manufacturing that aims to be implemented in 3D clay printing tasks. The purpose of this experimental study is to establish a first insight and provide information as well as guidelines for a comprehensive and robust additive manufacturing methodology that can be implemented in the area of 3D clay printing, aiming to be widely available and open for use in the relevant construction industry. Specifically, this paper emphasizes on the installation of an industrial extruder for 3D clay printing mounted on a robot, on toolpath planning process using a parametric design environment and on robotic execution of selected case studies. Based on existing 3D printing technology principles and on available rapid prototyping mechanisms, this process suggests an algorithm for system’s control as well as for robotic toolpath development applied in additive manufacturing of small to medium objects. The algorithm is developed in a parametric associative environment allowing its flexible use and execution in a number of case studies, aiming to tentatively test the effectiveness of the suggested robotic additive manufacturing workflow and their future implementation in large scale examples.
Autors: O. Kontovourkisa and G. Tryfonos
Modeling of Rough Surface and Contact Simulationijsrd.com
As a result of limitation of manufacturing processes, real surfaces always have some roughness and surface curvature. In many heat transfer applications, the perfectly smooth surfaces are necessary to transmit the heat. Due to the surface curvature of contacting bodies, the macro-contact area is formed, the area where micro-contacts are distributed randomly. The real contact occurs only over microscopic contacts. The heat flow must pass through the macro-contact and then micro-contacts to transfer from one body to another to form heat conductance. This phenomenon leads to a relatively high temperature drop across the interface. Thermal contact resistance (TCR) is a complex interdisciplinary problem, which includes geometrical, mechanical, and thermal analyses. In this paper, geometric modeling of asperities of rough surface 2 μm, 3.2 μm and 15μm surface roughness's is done in ANSYS and the number of asperities and areal contact area is found. The simulation is done with 1.8MPa pressure and with SS 304 as material for all above mentioned surface roughness's. The contacting bodies are kept at LN2 temperature and atmospheric temperature.
The article describes the design of the surface topography. The model uses
experimental data on the rough surface morphology. It is a 3-dimensional surface
microtopography. In case of incomplete or absent data, we can use statistically
processed parameters for longitudinal and transverse surface profiles. Taking into
account the possible inhomogeneity of the object of research, the microroughness of
generation uses a specially developed mathematical apparatus. The simulated surface
credibility. This approach makes it possible to estimate the parameters of each
surface microroughness. The analysis of the simulated and real surfaces. The actual
rough surface inhomogeneity causes discrepancies. It has been found that the
physical processes have been carried out during the contact. It has been found that
the process is to complete the process. The simulator has the highest possible
reliability. It is necessary to solve a specific engineering task. This software combines
a rough surface generation. It is a separate basic module modeling system.
Comparative studies on formability analysis in metal formingeSAT Journals
Abstract Sheet metal products are one of the most important semi-finished products used in the steel industry, and metal forming technology is therefore an important engineering domain. The development of new sheet metal forming processes, tooling and so on, has until now, to a large extent been based on experience, rules of thumb and trial- error experiments without or with only little use of scientifically based engineering methods. As mentioned above, experience is not enough, and trial-error experiments are expensive with regard to both money and time. The forming limit diagram (FLD) shows metal formability in metal forming with less cost. . The forming limit diagram typically represents the maximum permissible range of major and minor strains that a typical sheet material can undertake without failure. The forming limit diagram is experimentally measured for each sheet material by placing a grid of circle on the sheet sample and then deforming the same. A comparison of the original and the extensions in the marked grids on the sheet sample provide an estimate of the major and minor strain of the sample. This paper presents a case study of automotive component spring seat. By placing the grid of circles on the component and by measuring the dimensions of deformed circles a forming limit diagram has drawn. The simulations were carried out by fast form advanced software. The results achieved concluded that, safe forming zone is of bottom part and wrinkling tendency is present on side wall of component. Keywords: Forming, Forming limit diagram, Major strain, Minor strain, Safe zone, wrinkling
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity
Linking design and manufacturing on a PLM platformiosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Integrating parametric design with robotic additive manufacturing for 3D clay...Antonio Arcadu
ABSTRACT This paper presents an ongoing work in relation to the development of a parametric design algorithm and an automated system for additive manufacturing that aims to be implemented in 3D clay printing tasks. The purpose of this experimental study is to establish a first insight and provide information as well as guidelines for a comprehensive and robust additive manufacturing methodology that can be implemented in the area of 3D clay printing, aiming to be widely available and open for use in the relevant construction industry. Specifically, this paper emphasizes on the installation of an industrial extruder for 3D clay printing mounted on a robot, on toolpath planning process using a parametric design environment and on robotic execution of selected case studies. Based on existing 3D printing technology principles and on available rapid prototyping mechanisms, this process suggests an algorithm for system’s control as well as for robotic toolpath development applied in additive manufacturing of small to medium objects. The algorithm is developed in a parametric associative environment allowing its flexible use and execution in a number of case studies, aiming to tentatively test the effectiveness of the suggested robotic additive manufacturing workflow and their future implementation in large scale examples.
Autors: O. Kontovourkisa and G. Tryfonos
Modeling of Rough Surface and Contact Simulationijsrd.com
As a result of limitation of manufacturing processes, real surfaces always have some roughness and surface curvature. In many heat transfer applications, the perfectly smooth surfaces are necessary to transmit the heat. Due to the surface curvature of contacting bodies, the macro-contact area is formed, the area where micro-contacts are distributed randomly. The real contact occurs only over microscopic contacts. The heat flow must pass through the macro-contact and then micro-contacts to transfer from one body to another to form heat conductance. This phenomenon leads to a relatively high temperature drop across the interface. Thermal contact resistance (TCR) is a complex interdisciplinary problem, which includes geometrical, mechanical, and thermal analyses. In this paper, geometric modeling of asperities of rough surface 2 μm, 3.2 μm and 15μm surface roughness's is done in ANSYS and the number of asperities and areal contact area is found. The simulation is done with 1.8MPa pressure and with SS 304 as material for all above mentioned surface roughness's. The contacting bodies are kept at LN2 temperature and atmospheric temperature.
The article describes the design of the surface topography. The model uses
experimental data on the rough surface morphology. It is a 3-dimensional surface
microtopography. In case of incomplete or absent data, we can use statistically
processed parameters for longitudinal and transverse surface profiles. Taking into
account the possible inhomogeneity of the object of research, the microroughness of
generation uses a specially developed mathematical apparatus. The simulated surface
credibility. This approach makes it possible to estimate the parameters of each
surface microroughness. The analysis of the simulated and real surfaces. The actual
rough surface inhomogeneity causes discrepancies. It has been found that the
physical processes have been carried out during the contact. It has been found that
the process is to complete the process. The simulator has the highest possible
reliability. It is necessary to solve a specific engineering task. This software combines
a rough surface generation. It is a separate basic module modeling system.
Comparative studies on formability analysis in metal formingeSAT Journals
Abstract Sheet metal products are one of the most important semi-finished products used in the steel industry, and metal forming technology is therefore an important engineering domain. The development of new sheet metal forming processes, tooling and so on, has until now, to a large extent been based on experience, rules of thumb and trial- error experiments without or with only little use of scientifically based engineering methods. As mentioned above, experience is not enough, and trial-error experiments are expensive with regard to both money and time. The forming limit diagram (FLD) shows metal formability in metal forming with less cost. . The forming limit diagram typically represents the maximum permissible range of major and minor strains that a typical sheet material can undertake without failure. The forming limit diagram is experimentally measured for each sheet material by placing a grid of circle on the sheet sample and then deforming the same. A comparison of the original and the extensions in the marked grids on the sheet sample provide an estimate of the major and minor strain of the sample. This paper presents a case study of automotive component spring seat. By placing the grid of circles on the component and by measuring the dimensions of deformed circles a forming limit diagram has drawn. The simulations were carried out by fast form advanced software. The results achieved concluded that, safe forming zone is of bottom part and wrinkling tendency is present on side wall of component. Keywords: Forming, Forming limit diagram, Major strain, Minor strain, Safe zone, wrinkling
Role of Simulation in Deep Drawn Cylindrical PartIJSRD
Simulation is widely used in forming industry due to its speed and lower cost and it has been proven to be effective in prediction of formability and spring back behavior. The purpose of finite element simulation in the sheet metal forming process is to minimize the time and cost in the design phase by predicting key outcomes such as the final shape of the part, the possibility of various defects and the flow of material. Such simulation is most useful and efficient when it is performed in the early stage of design by designers, rather than by analysis specialists after the detailed design is complete. The accuracy of such simulation depends on knowledge of material properties, boundary conditions and processing parameters. In the industry today, numerical sheet metal forming simulation is very important tool for reducing load time and improving part quality. In this paper finite element model for the deep-drawing of cylindrical cups is constructed and the simulation results are obtained by using different simulation parameters, i.e. punch velocity, coefficient of friction and blank holder force of the FE mesh-elements and these results are compared with experimental work.
CFD SIMULATION OF SOLDER PASTE FLOW AND DEFORMATION BEHAVIOURS DURING STENCIL...ijmech
In 20th century, Electronics elements have become most significant part of the regular life. The main heart
of electronic element is PCB which supports and manages mostly machines and equipments these days.
Therefore manufacturing of board and assembly of electronic elements is one of the crucial and significant
objectives for most of the companies. Better life of PCB’s depends on electronic elements and its assembly
with board. Solder paste is used as adhesive material for assembly purpose. It is deposited on board using
stencil and electronic elements are mounted on it and heated for strong bond.
This study investigates on factors affecting stencil printing process due to variation in squeegee speed and
density of solder paste. This study is based on computational fluid dynamics virtual simulation. Prototype is
developed for modelling purpose and simulation software is used to simulate the flow behaviour of solder
paste during stencil printing process.
A Study on Thermo-Mechanical Analysis of Hot Rolling & Estimation of Residual...IOSR Journals
The major problem in rolling process is the defects like fire cracks, severe sticking in a billet mill,
and etc. This paper deals with the study on reducing or minimizing the defects of rolling process. The analysis
has been carried out for different temperature i.e. 100°c, 150°c, 200°c, 250°c. As the temperature goes on
increasing correspondingly the residual stresses decreases. Hot rolling process helps in reduced residual
stresses at high temperature & helps in formation of smooth granular structure of product. Due to the symmetry
of the rolling components, half the model is built & the analysis is carried out with 4 roller sizes varying from
8mm to 20mm with 4mm increment & the results were tabulated by using ANSYS. This will helps in estimation
of residual stresses.
Additive manufacturing (AM) or additive layer manufacturing (ALM) is the industrial production name for 3D printing, a computer controlled process that creates three dimensional objects by depositing materials, usually in layers.
AM is a rapidly growing field that is having an impact on multiple industries by simplifying the process to go from a 3D model to a finished product.
In contrast to conventional manufacturing processes, AM fabricates objects by adding materials as required which eliminates the necessity of subtracting materials (by means of machining, milling, carving, etc.) to obtain desired shapes.
AM can advantageously fabricate complex geometries with no part-specific tooling and much less waste material.
In the construction sector, architectural models have been created with AM methods for more than a decade.
Recent years have seen a vast increase in research on printing methods for building components.
AM allows building companies to produce geometrically complex structures, to vary materials within a component according to its functions, and to automate the construction process starting from a digital model.
The technology can bring significant benefits to the construction industry in terms of increased customization, reduced construction time, reduced manpower, and construction cost.
Numerical and Theoretical Analysis for Investigation of Shear strength of A J...ijsrd.com
It is becoming increasingly important to accurately predict the behavior of adhesive joints. Adhesive joints are widely used in industries e.g. automobiles, aircrafts, home appliances and so on. They are being used as a closure system in the packaging industry, through the use of adhesives as a system for construction of complex structures such as skyscrapers, airplanes, trains or buses etc. In adhesive bonding, the load is transmitted from one adherend to another adherend smoothly through the adhesive layer in the overlap region i.e. the adhesive serves as medium for load transmission. The research is presented with variants of different adhesive materials proposed for the shear strength investigation of adhesive joint to be used in the automotive industry. The problem is investigated using mathematical analysis as well as analytical methodology with Finite Element Analysis. For meshing of the geometry of the brake shoe assembly hyper mesh software is used. In FEA, the competent software ‘Abacus’ is used for determining the shear stress induced in two different materials of adhesive layer applied to the brake shoe. Different variants with different adhesive materials and geometry of base material are analyzed for concluding the research work.
DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANELIjripublishers Ijri
A plastic material is any of a wide range of synthetic or semi-synthetic organic solids that are moldable. Plastics are
typically organic polymers of high molecular mass, but they often contain other substances. They are usually synthetic,
most commonly derived from petrochemicals, but many are partially natural.
Molding is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or
matrix. This itself may have been made using a pattern or model of the final object.
Cooling channels are used in mold tool to reduce the temperature of the object to help molten material to solidify quickly
before the ejection. It is quite useful to increase the production rate.
DESIGN OF MOULD TOOL & COOLING CHANNEL OPTIMIZATION OF REMOTE CONTROL TOP PANELIjripublishers Ijri
A plastic material is any of a wide range of synthetic or semi-synthetic organic solids that are moldable. Plastics are
typically organic polymers of high molecular mass, but they often contain other substances. They are usually synthetic,
most commonly derived from petrochemicals, but many are partially natural.
Molding is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or
matrix. This itself may have been made using a pattern or model of the final object.
Cooling channels are used in mold tool to reduce the temperature of the object to help molten material to solidify quickly
before the ejection. It is quite useful to increase the production rate.
The aim of this project work is to design mold structure and optimize cooling channel system to reduce effect of warpage
of remote control top panel.
A Review on Finite Element Analysis of Automobile roof header Manufactured By...ijiert bestjournal
In stamping operations,sheet metal is formed into a desired s hape by pressing it in a hydraulic or mechanical press between suitably shaped dies. As a predominant manufacturing pr ocess,sheet metal forming has been widely used for the production of automobiles,aircraft,home appliance s,beverage cans and many other industrial and commercial products. Given that the press force itsel f is an integral of the contact pressure distribution over the die and binder contact interfaces,it is concei vable that defects may be better identified by analyzing the contact pressure distribution directly at the tooling-work piece interface.
Influence of contact friction conditions on thin profile simulationVan Canh Nguyen
The paper presents the development of the Finite Element model for simulation of thin
aluminium profile extrusion of both solid and hollow shapes. The analysis has shown that the material
flow in simulation is very dependent on the friction model. Experimental and theoretical studies show
that friction traction on the interface between the tool and the deformed material can be represented as
a combination of adhesive friction force and the force that is required to deform surface asperities. In
aluminium extrusion we can clearly distinguish two different areas with respect to friction conditions
such as sticking and sliding and transient zones between them. The lengths of these zones are also
dependent on variation of the choke angle and actual thickness of the profile. To get these values the
material flow problem is to be coupled with the simulation of the tools deformation. A series of
experiments with specially designed tools have been done to investigate how the bearing length and
choke angle may influence the extension of different friction zones and by these means vary the
material flow pattern. The friction models have also been tested with industrial profiles of complex
shapes and have shown good correspondence to reality.
The Roman Empire A Historical Colossus.pdfkaushalkr1407
The Roman Empire, a vast and enduring power, stands as one of history's most remarkable civilizations, leaving an indelible imprint on the world. It emerged from the Roman Republic, transitioning into an imperial powerhouse under the leadership of Augustus Caesar in 27 BCE. This transformation marked the beginning of an era defined by unprecedented territorial expansion, architectural marvels, and profound cultural influence.
The empire's roots lie in the city of Rome, founded, according to legend, by Romulus in 753 BCE. Over centuries, Rome evolved from a small settlement to a formidable republic, characterized by a complex political system with elected officials and checks on power. However, internal strife, class conflicts, and military ambitions paved the way for the end of the Republic. Julius Caesar’s dictatorship and subsequent assassination in 44 BCE created a power vacuum, leading to a civil war. Octavian, later Augustus, emerged victorious, heralding the Roman Empire’s birth.
Under Augustus, the empire experienced the Pax Romana, a 200-year period of relative peace and stability. Augustus reformed the military, established efficient administrative systems, and initiated grand construction projects. The empire's borders expanded, encompassing territories from Britain to Egypt and from Spain to the Euphrates. Roman legions, renowned for their discipline and engineering prowess, secured and maintained these vast territories, building roads, fortifications, and cities that facilitated control and integration.
The Roman Empire’s society was hierarchical, with a rigid class system. At the top were the patricians, wealthy elites who held significant political power. Below them were the plebeians, free citizens with limited political influence, and the vast numbers of slaves who formed the backbone of the economy. The family unit was central, governed by the paterfamilias, the male head who held absolute authority.
Culturally, the Romans were eclectic, absorbing and adapting elements from the civilizations they encountered, particularly the Greeks. Roman art, literature, and philosophy reflected this synthesis, creating a rich cultural tapestry. Latin, the Roman language, became the lingua franca of the Western world, influencing numerous modern languages.
Roman architecture and engineering achievements were monumental. They perfected the arch, vault, and dome, constructing enduring structures like the Colosseum, Pantheon, and aqueducts. These engineering marvels not only showcased Roman ingenuity but also served practical purposes, from public entertainment to water supply.
Palestine last event orientationfvgnh .pptxRaedMohamed3
An EFL lesson about the current events in Palestine. It is intended to be for intermediate students who wish to increase their listening skills through a short lesson in power point.
Synthetic Fiber Construction in lab .pptxPavel ( NSTU)
Synthetic fiber production is a fascinating and complex field that blends chemistry, engineering, and environmental science. By understanding these aspects, students can gain a comprehensive view of synthetic fiber production, its impact on society and the environment, and the potential for future innovations. Synthetic fibers play a crucial role in modern society, impacting various aspects of daily life, industry, and the environment. ynthetic fibers are integral to modern life, offering a range of benefits from cost-effectiveness and versatility to innovative applications and performance characteristics. While they pose environmental challenges, ongoing research and development aim to create more sustainable and eco-friendly alternatives. Understanding the importance of synthetic fibers helps in appreciating their role in the economy, industry, and daily life, while also emphasizing the need for sustainable practices and innovation.
Read| The latest issue of The Challenger is here! We are thrilled to announce that our school paper has qualified for the NATIONAL SCHOOLS PRESS CONFERENCE (NSPC) 2024. Thank you for your unwavering support and trust. Dive into the stories that made us stand out!
How to Create Map Views in the Odoo 17 ERPCeline George
The map views are useful for providing a geographical representation of data. They allow users to visualize and analyze the data in a more intuitive manner.
How to Split Bills in the Odoo 17 POS ModuleCeline George
Bills have a main role in point of sale procedure. It will help to track sales, handling payments and giving receipts to customers. Bill splitting also has an important role in POS. For example, If some friends come together for dinner and if they want to divide the bill then it is possible by POS bill splitting. This slide will show how to split bills in odoo 17 POS.
Ethnobotany and Ethnopharmacology:
Ethnobotany in herbal drug evaluation,
Impact of Ethnobotany in traditional medicine,
New development in herbals,
Bio-prospecting tools for drug discovery,
Role of Ethnopharmacology in drug evaluation,
Reverse Pharmacology.
Model Attribute Check Company Auto PropertyCeline George
In Odoo, the multi-company feature allows you to manage multiple companies within a single Odoo database instance. Each company can have its own configurations while still sharing common resources such as products, customers, and suppliers.
Welcome to TechSoup New Member Orientation and Q&A (May 2024).pdfTechSoup
In this webinar you will learn how your organization can access TechSoup's wide variety of product discount and donation programs. From hardware to software, we'll give you a tour of the tools available to help your nonprofit with productivity, collaboration, financial management, donor tracking, security, and more.
Welcome to TechSoup New Member Orientation and Q&A (May 2024).pdf
42
1. SOME RECENT SIMULATION CASES OF COLD
FORMING WITH DEFORM™-3D
B. K. Chun, J. Fluhrer, M. Foster, G. Li and W.-T. Wu
Scientific Forming Technologies Corporation, Columbus, Ohio, U.S.A.
Abstract
Tremendous progress in numerical analyses of metal forming processes has been achieved in the recent
years and the finite element simulation has become a powerful tool in many industries. Trends of
development of simulation technology are summarized. Some recent applications of the DEFORM™-3D
system to a wide range of cold metal forming and associated processes are presented, including mesh-to-
mesh contact cases and a thread rolling example.
Introduction
In the last decade, industrial acceptance of metal forming modeling with the finite element method (FEM)
has increased so rapidly that its industrial applicatons have become routine as the technology continues to
spread.
The advent of simulation technology in metal forming could not have come at a better time when
computer hardware has experienced dramatic price reduction and speed increases. PCs have become so
powerful as well as affordable that their popularity has surpassed that of workstations. The dream to
carry a laptop with a simulation running on it to the plant, conference room or onboard a plane has come
to fruition.
The finite element formulations for various material models have become mature [1, 2]. The updated
Lagrangian approach still dominates most of the forming applications, but the ALE approach also finds
increasing applications. Tetrahedral elements using a mixed formulation and hexahedral elements are
found most suitable for large plastic deformation. The wider use of tetrahedral elements is supported by
mesh generators, which now can successfully create tetrahedral meshes with great complexity and with
large contrast in element sizes to model a variety of processes in the forming industries. All of these have
improved the ability to analyze complex three-dimensional forming processes accurately and efficiently
and have opened up additional avenues for the application of simulation. The commercial programs
integrate the finite element technology into comprehensive software systems, complemented by improved
graphical user interfaces, thus making themselves very user-friendly and flexible. It is not suprising that
many forming engineers and researchers find such tools essential.
Mature applications of metal forming simulation include the prediction of the material flow, die fill and
loading condition [3]. The information thus obtained can be used for process design, defect prediction or
analysis, and cost analysis. The scope of simulation continues to broaden as the recent trends are
discussed as follows.
The combination of modeling individual processes have evolved into the development of progressions
and tool and die design [4]. Optimizing the progression design using process simulation is superior to
trial-and-error on the shop floor. In the development of metal forming progressions, the designer
balances many complex parameters to accomplish a workable progression design. These parameters
2. include the number of intended operations, required volumetric displacements, final part geometry,
starting material size, available forming equipment and the behavior of the workpiece. In conjunction
with the progression development, a multiple operation template can be designed to integrate a series of
individual operations into a complete job to facilitate the simulation management, so the modeling work
can be carried out as an automated processes.
New finite element applications to more sophisticated and complicated forming processes are
continuously being explored. These continuous challenges have enriched the repertoire of the simulation
technology.
In addition, process simulation capabilities have been expanded to some associated areas beyond forming
modeling. Die stress analysis has been shown to be a very cost-effective use of simulation. Die costs
have been estimated at 5 to 15% of the cost of sales. It is noted that the dies are typically subjected to a
severe operating environment due to the high interface pressure experienced in the manufacture of cold-
formed parts. In warm and hot forming, these effects are compounded by extreme temperatures.
Similarly, die wear analysis can also be conducted using the FEM results.
In order to achieve a desirable combination of microstructure, mechanical properties, residual stresses and
dimensional accuracy in the final product, a heat treatment process that involves several heating and
cooling cycles may be employed. Each cycle could involve complex thermal boundary conditions, e.g.,
air/fan cooling, oil/water quenching, and furnace/induction heating. The material responds to the
complex coupling of stress, microstructural and chemical (carburizing and nitriding) conditions over a
wide range of temperatures. Designing a heat treatment process sequence is complex and has generally
been done based on experience, as was the case with forming prior to process simulation. With the
advent of heat treatment simulation, it is now possible to detect, understand and correct potential heat
treatment problems early in the manufacturing process cycle through the use of simulation.
Another active field of finite element research is the modeling of machining processes. This includes the
numerical analysis of chip formation and the part distortion after material removal.
In the following sections, the use of DEFORM™ as a design tool for selected cold forming applications is
presented.
Mesh-to-Mesh Contact
The contact problem is most challenging in the finite element analysis of forming processes. If contact
phenomena cannot be appropriately modeled the accuracy of the simulation results will be compromised.
As a mesh in the finite element analysis represents a deforming workpiece, the contact algorithm should:
- Enforce the normal constraint to a contact node so as to prevent it from penetrating into the other side
it is in contact with;
- Apply the tangential friction to the contact node in the direction opposite to the relative movement:
and
- Release the node from the contact status once it is detected of being pulled by the other side.
There are two types of contact in the finite element technology. Mesh-to-die contact deals with the
contact of a workpiece with a non-deforming rigid die. Mesh-to-mesh contact, on the other hand, is
3. concerned with the contact between two meshed parts of the same object or two different objects. Of the
two contact types, the mesh-to-die contact is well established and therefore will not be discussed here.
The mesh-to-mesh contact models the interaction between the two meshed parts in the contact area. It in
turn can be subdivided into: (1) contact between two deforming workpieces, and (2) contact between two
parts of a single workpiece (self-contact) and (3) coupling for rotational (or cyclical) symmetry.
In a static structural analysis of simple geometry, if we can create a mesh system in such a way that there
are always node-to-node contact pairs connecting both sides in the contact area, their coupling can be
readily implemented without much difficulty. However, in the metal forming applications, when the part
geometry is complicated, it is quite difficult to generate a mesh that meets this requirement. Even if such
a mesh is generated, the two contacting parts are prone to slide along each other when both sides are
subject to large deformation. Naturally, the node-to-node coupling cannot be maintained. Generally, the
node-to-segment or segment-to-segment coupling has to be established. Here a segment is a surface
element edge in 2D cases or a surface triangle or quadrilateral in 3D cases.
Being able to handle the mesh-to-mesh contact, DEFORM™-3D has been used to analyze many multi-
deforming object cases, self-contact cases and cases with rotational symmetry. Three cold forming
examples are presented here to illustrate the contact treatment.
Self-Contact
Fig. 1 is a heat sink in an electronics product made of Al 5052. A shallow rectangular recess 1.5 mm
deep is required on a plate part 2.35 mm thick. The original manufacturing method was to machine the
recess, which is quite inefficient, so stamping is used instead. If the recess is formed from a solid part, to
remove the excessive material requires considerable force and the part will experience large distortion.
An improved design is to punch an elliptical hole in the center together with blanking. Then the recess is
coined, while the hole is closing up. To justify this idea and to determine the optimal size and shape of
the initial hole, the simulation was conducted during the process design.
Fig. 2 shows the meshes used at the beginning and ending of the recess coining. Due to the symmetry,
only a half of the part is actually modeled. The two small round indentions are omitted for simplicity.
(a) (b)
Fig. 1 Heat sink: (a) top view and (b) bottom view.
4. (a) (b)
Fig. 2 FEM meshes: (a) beginning and (b) near ending.
Fig. 3 shows the evolution of the shrinking hole. The upper series is the flownet, through which the
material flow can be observed. The lower series are the top view of the part at different stages. From a
certain stage in the process, the sidewall of the hole starts touching itself. It is at this stage where the self
contact capability is tested. Eventually the contact length grows until the hole becomes a seam. It should
be mentioned that without a powerful mesh generator, this simulation could not have been completed.
It is interesting to note from the strain distribution in Fig. 4 that large strains are accumulated at both ends
of the seam. Actually the two ends of the seam is closing up more slowly and there are two tiny holes left
in the part even the whole seam is tightly formed, which can be seen on the real part in Fig 1. The
simulation has correctly reproduced the reality in detail.
Fig. 3 The evolution of the central hole to a closed-up seam in simulation:
upper half -- flownet; lower half – shaded view.
5. Fig. 4 The strain distribution: top view and on the central cross-section.
Multiple Deforming Objects
The second example is a nut assembly (Fig. 5), in which two stamped parts are to be joined together in an
assembling die. The original nut and plate are shown. Fig. 6 illustrates how the two meshed objects are
put together at the beginning of simulation.
When the stamping begins, the punch pushed the nut downward, thus upsetting the two upturned
tongues on the plate to fill up the slots on the nut until the two parts form a tight joint.
(a)
Fig. 5 FEM meshes of the initial parts to be
joined together: (a) the plate and (b) the nut (b)
(top - picture of the real part; bottom – FEM mesh)
6. Fig. 6 Initial FEM meshes of the two parts put together.
Fig. 7 is the effective strain pattern in both parts at different stages of assembling. It is visible in Fig.
7-a that at the beginning, there are gaps between the tongues of the plate and the slots on the nut.
When the nut is pushed down by the punch, the tongues first begin to bend downwards. At Step 30
(a) (b)
(c) (d)
Fig. 7 Strain pattern at various stages:
(a) Step 20, (b) Step 30, (c) Step 35 and (d) Step 42.
7. (Fig. 7-b), the tongues have fully filled the slots. The localized deformation of the two tongues (Fig. 7-c
and -d) is desirable, as it makes them expand sideways and thus a tight joint with the nut can be possible.
It is clear that this simulation would not have been possible without the mesh-to-mesh contact treatment.
Rotational Symmetry
Rotational symmetry is a special case of self-contact. When a part repeats itself cyclically, we can model
a small “pie” segment of it to reduce the complexity of the simulation, or to increase the accuracy by
using finer elements. This is achieved by coupling the two sides of the segment model, i.e., any
corresponding two points on both sides of the pie should have the same velocity with the respect to its
central line.
The helical gear in Fig. 8 is a good example for rotational symmetry. Historically helical gears were
machined at a high cost from round stocks. A cold-formed process to develop net shape helical gear
components was developed by the Yamanaka Engineering Corporation in Japan. The gear with eight
teeth (Fig. 8-b) is extruded from an AISI 1035 round stock of 28 mm OD with a fillet at the bottom edge
(Fig. 8-a). The regular full model is simulated for comparison.
The rotational symmetry takes only one-eighth of the material (Fig. 9-a) with two slicing planes 45
degrees apart. As the material is squeezed into the extrusion die, the slicing planes automatically become
twisted surfaces, following the spiral curve. The deformation at different stages is shown in Fig. 10. The
quality and stability of the coupling is important in simulation. This can be examined by graphically
assembling the segments into a whole part (Fig. 11). On the mating surfaces, there should be no gaps or
overlaps. Good agreement between the strain patterns obtained from the one-eighth and full models at
the final stage of deformation is presented in Figs. 12 and 13, respectively.
(a) (b) (c)
Fig. 9 The extrusion of a helical gear – full model:
(a) initial billet; (b) and (c), final stage.
8. (a) (b)
Fig. 10 The extrusion of a helical gear – one-eighth model:
(a) initial billet; (b) Step 391 and (c), Step 511. (c)
(a) (b)
Fig. 11 The assembled image of the repeated one-eighth model at the final stage
9. (a) (b)
Fig. 12 The strain distribution, repeated image of one-eighth model at the final stage.
(a) (b)
Fig. 13 The strain distribution, full model, at the final stage.
10. Thread Rolling Simulation and Stress Analysis of the Die
Threaded fasteners are used in most mechanical assemblies. Machining or rolling generally forms the
threads. Turning or grinding processes can also be used to produce machined threads. Machined threads
are cut into the screw or bolt by removing the material. On the other hand, threads can be cold formed on
the blank using hardened steel dies.
Thread rolling has several major advantages over thread machining:
- The deformation involved in the rolling process work hardens the threads, resulting in increased
strength.
- Rolled threads have improved fatigue resistance. The rolling process puts the surface in a state of
compression, making it more difficult for crack formation and propagation to occur. The grain structure
in a rolled thread is continuous, as opposed to the cut grains found in a machined product.
- Rolled threads typically have superior surface finish and a lower cost relative to machined threads.
The major challenges for such a simulation are simulation speed, meshing and handling of the rotational
movement. The considerable contrast in mesh densities over different parts is necessary, as the threads
need to be constructed of very fine elements. This increases the total problem size and computing time.
The total turn around time is multiplied by the many revolutions of the bolt needed to complete the thread
formation. As a result of continuous development, the thread rolling process now can be modeled in
DEFORM™-3D, and can be used to investigate thread formation, underfill and stress in the threading
dies.
The images shown are from a thread rolling simulation that was run on a desktop PC in approximately
one day. The simulation was set up based on a translational threading rolling machine. The blank,
coming from the header, is placed between the two threading dies, and then one of the dies moves in
translation while the other die remains stationary. The friction between the blank and the dies causes the
blank to spin. As the blank is rolled, the threads are formed (Fig. 14).
(a) (b)
Fig.13 TheFEMmeshesareshown(a)atthebeginningand(b)attheend ofthethreadrollingsimulation.
11. Fig. 14 The process of thread rolling.
(a) (b)
Fig. 15 Die matching before the simulation starts:
(a) die position; and (b) examination on a slicing plane.
13. Fig.19Theeffectivestress (redishigher)isshownonthethreadrollingdie
neartheendoftheformingprocess.
Before a thread rolling simulation can be run, the dies need to be matched. Position the dies in the
starting position, and then slice them down the center of the bolt. Thread root (top die) needs to
correspond to thread tip (bottom die). The velocity plotting is shown in Fig. 16 and the strain
distribution is shown in Fig. 17.
In addition to the thread filling study, the elastic stress analysis is often needed for the threading dies.
The threading dies used in the rolling simulations are quite large compared to the bolt itself. When
performing stress analysis on the dies, a subdomain of the original die geometry was used (Fig. 18). The
effective stress of one of the dies is shown in Fig. 19.
Summary
Recently, the finite element-based software has become an integral part of process and progression
design and research in the forming industries to analyze and optimize the metal flow and to minimize the
die stress and tool wear. The industrial acceptance of this computer-aided engineering system could not
have achieved without the significant progress in the finite element theory and practice and the rapid
advances in computer technology.
In this paper, a few selected cold forming simulations by using DEFORMTM
-3D are presented. These
examples demonstrate the important part of finite element contact technology for the multiple
deformation bodies problems, and capability to handle large rotational problem such as thread rolling.
Although the FEM has proven itself to the forming industry, the development of finite element
technology will always be challenged by the newer and wider scope: the entire manufacturing processes.
14. References
[1] Kobayshi, S; Oh, S; Altan, T: Metal forming and finite element method, Oxford Univ. Press,
1989.
[2] Wagoner, RH; Chenot, JL: Metal forming analysis, Cambridge Univ. Press, 2001.
[3] Altan, T; Ngaile, G; Shirgaokar, M: State of cold forging technology in global competition, in
Siegert, K, ed.: New Developments in forging technology, Fellbach, Germany, 2003.
[4] Walters, J; Wu, WT; Hermann, M: The simulation of bulk forming processes with DEFORMTM
,
ibid.
[5] Wu, WT; Jinn, JT; Yang, JB; Oh, JY; Li, G: The finite element method and manufacturing
processes, Proceedings of the 6th
ESAFORM Conference on Material Forming, Salerno, Italy, 2003.