The document discusses the use of computer simulation software in forging industries. It describes what a simulation is and provides examples of forging simulation software, including Transvalor forge, Deform 3D, and QForm. It then focuses on the DEFORM software, outlining that it is a finite element method simulation system designed for metal forming processes. The major components of DEFORM are described as the pre-processor, simulation, and post-processor. The functions of each component, such as creating input data and displaying results, are summarized. Finally, the advantages and disadvantages of using simulation software are briefly presented.
This document is a thesis submitted by Kerem Karakoc for the degree of Master of Applied Science in Mechanical Engineering. It presents the development of a novel electromechanical brake (EMB) system for automotive applications using a magnetorheological (MR) brake. The MR brake design process includes magnetic circuit design, material selection, sealing, cooling considerations and optimization of key design parameters using finite element analysis and experimental validation of a prototype. Simulation results show the braking torque generation of the optimized design but there are discrepancies with experimental results likely due to modeling assumptions. Suggestions for further improving the braking torque capacity are discussed.
This document provides guidance on architecting and deploying MetroCluster configurations, including an overview of MetroCluster, planning considerations, installation steps, and best practices. It covers stretched, switched, and fabric MetroCluster topologies using NetApp storage and includes configuration examples for 16-port and 8-port Brocade switches. The intended audience is field personnel responsible for MetroCluster implementations.
In the recent decades of development of manufacturing and production engineering, 3D printing technology has emerged as one of the most promising area for research and development. With the availability of flexible and user friendly manufacturing and interfacing system, the 3D printing technology has attracted a lot of researchers form keen aspects of their field.
Medical Engineering is the branch of science that deal with the application of technological aspects in solving medical problems. With the merger in these two vast fields a lot of problems has been answered and the development of new things is on their verge of initiation.
In the recent decade both the engineers and medical researchers have worked on integration of technologies to solve the medical problems globally. In the scenario, a lot of technology like 3D printed Heart, Kidneys, etc., & physical implants like teeth’s, bones and medical support.
In this report, I have tried to acknowledge the work done in the field with their importance in the ever changing scenario of the world.
The document discusses modal analysis of a high-speed milling spindle. A finite element model of the spindle is created in ANSYS based on its specifications. Modal analysis of the model yields natural frequencies including 422 Hz. Experimental modal analysis using an FFT analyzer on a manufactured spindle specimen yields frequencies up to 401 Hz. Comparing the finite element and experimental results, 422 Hz is identified as the natural resonance frequency of the spindle, which is above the designed operating speed of 16,000 rpm. The modal analysis shows no resonance will occur during operation.
Finite element optimization of stator by casted and welded structureseSAT Publishing House
1) The document discusses finite element optimization of the structure of a stator that can be made by either casting or welding.
2) Finite element models of both the casted and welded stator structures were created and analyzed under the applied loads to compare their performance.
3) An optimization analysis was performed on the casted structure model by varying 11 design parameters to minimize the weight while meeting the stress and displacement criteria. The optimized casted design required 504kg of material.
Fabrication and Analysis of Fatigue Testing Machinetheijes
The document describes the fabrication and analysis of a fatigue testing machine. Key points:
- The machine subjects material specimens to repeated cyclic loading to determine their fatigue strength and create S-N curves.
- Components include a motor, bearings, frame, testing specimens of mild steel and stainless steel, a sensor, and digital counter.
- Testing of the materials generated S-N curves and estimated their endurance limits, which were within 20% of actual values.
- The design provides an affordable way to experimentally determine fatigue properties of materials through cyclic loading tests.
COMPUTATIONAL ENGINEERING OF FINITE ELEMENT MODELLING FOR AUTOMOTIVE APPLICAT...IAEME Publication
Modals with complicated geometry, complex loads and boundary condition are difficult to analyse and evaluate in the terms of strain, stress, displacement and reaction forces by using theoretical methods. A given modal can be analysed by using Finite Element Method easily with the help of computer software ABAQUS CAE and can get approximate solutions. This report is about modelling two dimensional and three dimensional analyses with the ABAQUS CAE for plane stress, plane strain, shell, and beam and 3d solid modal elements.
The document discusses the use of computer simulation software in forging industries. It describes what a simulation is and provides examples of forging simulation software, including Transvalor forge, Deform 3D, and QForm. It then focuses on the DEFORM software, outlining that it is a finite element method simulation system designed for metal forming processes. The major components of DEFORM are described as the pre-processor, simulation, and post-processor. The functions of each component, such as creating input data and displaying results, are summarized. Finally, the advantages and disadvantages of using simulation software are briefly presented.
This document is a thesis submitted by Kerem Karakoc for the degree of Master of Applied Science in Mechanical Engineering. It presents the development of a novel electromechanical brake (EMB) system for automotive applications using a magnetorheological (MR) brake. The MR brake design process includes magnetic circuit design, material selection, sealing, cooling considerations and optimization of key design parameters using finite element analysis and experimental validation of a prototype. Simulation results show the braking torque generation of the optimized design but there are discrepancies with experimental results likely due to modeling assumptions. Suggestions for further improving the braking torque capacity are discussed.
This document provides guidance on architecting and deploying MetroCluster configurations, including an overview of MetroCluster, planning considerations, installation steps, and best practices. It covers stretched, switched, and fabric MetroCluster topologies using NetApp storage and includes configuration examples for 16-port and 8-port Brocade switches. The intended audience is field personnel responsible for MetroCluster implementations.
In the recent decades of development of manufacturing and production engineering, 3D printing technology has emerged as one of the most promising area for research and development. With the availability of flexible and user friendly manufacturing and interfacing system, the 3D printing technology has attracted a lot of researchers form keen aspects of their field.
Medical Engineering is the branch of science that deal with the application of technological aspects in solving medical problems. With the merger in these two vast fields a lot of problems has been answered and the development of new things is on their verge of initiation.
In the recent decade both the engineers and medical researchers have worked on integration of technologies to solve the medical problems globally. In the scenario, a lot of technology like 3D printed Heart, Kidneys, etc., & physical implants like teeth’s, bones and medical support.
In this report, I have tried to acknowledge the work done in the field with their importance in the ever changing scenario of the world.
The document discusses modal analysis of a high-speed milling spindle. A finite element model of the spindle is created in ANSYS based on its specifications. Modal analysis of the model yields natural frequencies including 422 Hz. Experimental modal analysis using an FFT analyzer on a manufactured spindle specimen yields frequencies up to 401 Hz. Comparing the finite element and experimental results, 422 Hz is identified as the natural resonance frequency of the spindle, which is above the designed operating speed of 16,000 rpm. The modal analysis shows no resonance will occur during operation.
Finite element optimization of stator by casted and welded structureseSAT Publishing House
1) The document discusses finite element optimization of the structure of a stator that can be made by either casting or welding.
2) Finite element models of both the casted and welded stator structures were created and analyzed under the applied loads to compare their performance.
3) An optimization analysis was performed on the casted structure model by varying 11 design parameters to minimize the weight while meeting the stress and displacement criteria. The optimized casted design required 504kg of material.
Fabrication and Analysis of Fatigue Testing Machinetheijes
The document describes the fabrication and analysis of a fatigue testing machine. Key points:
- The machine subjects material specimens to repeated cyclic loading to determine their fatigue strength and create S-N curves.
- Components include a motor, bearings, frame, testing specimens of mild steel and stainless steel, a sensor, and digital counter.
- Testing of the materials generated S-N curves and estimated their endurance limits, which were within 20% of actual values.
- The design provides an affordable way to experimentally determine fatigue properties of materials through cyclic loading tests.
COMPUTATIONAL ENGINEERING OF FINITE ELEMENT MODELLING FOR AUTOMOTIVE APPLICAT...IAEME Publication
Modals with complicated geometry, complex loads and boundary condition are difficult to analyse and evaluate in the terms of strain, stress, displacement and reaction forces by using theoretical methods. A given modal can be analysed by using Finite Element Method easily with the help of computer software ABAQUS CAE and can get approximate solutions. This report is about modelling two dimensional and three dimensional analyses with the ABAQUS CAE for plane stress, plane strain, shell, and beam and 3d solid modal elements.
The document provides installation instructions for DEFORMTM 3D Version 6.1 software. It notes an important change in the password location and details how to install the security key device and DEFORMTM program files. The instructions outline accepting license agreements, selecting installation directories, and rebooting to complete the process. Users are directed to contact support for any installation questions or problems.
Simulation of the Surface Hardening of a Forged CrankshaftGeonx
Adhish Majumdar of GEONX delivered on 18th May 2016 a presentation on the "Simulation of the Surface Hardening of a Forged Crankshaft using High Performance Computing" at the second edition of the ICOMP conference held at Liège, Belgium.
This document is the user manual for DEFORM 3D Version 6.0, a software for analyzing manufacturing processes. It provides an overview of DEFORM's capabilities for simulating metal forming processes, as well as descriptions of the pre-processor for setting up simulations, defining objects and materials, generating meshes, and applying boundary and initial conditions. It also covers using the post-processor to view results and running simulations in interactive or batch modes.
Computer Aided Process Planning (CAPP): concepts; traditional and CAPP; automated
process planning: process planning, general methodology of group technology, code
structures of variant and generative process planning methods, AI in process planning,
process planning software.
Flexible Manufacturing Systems (FMS): Introduction, types, concepts, need and
advantages of FMS - cellular and FMS - JIT and GT applied to FMS.
Optimisation of machining parameters for slot milling operation in Inconel 62...Denny John
Vikram Sarabhai Space Centre (VSSC) is the lead centre for development of satellite launch vehicles and technologies in India. It was established in 1963 as Thumba Equatorial Rocket Launching Station and renamed after Dr. Vikram Sarabhai in 1971. VSSC's major programmes include Polar Satellite Launch Vehicle (PSLV), Geosynchronous Satellite Launch Vehicle (GSLV), and it has made significant contributions to India's space programmes, including the Chandrayaan-1 mission to the moon.
Inconel 625 is a nickel-based super alloy widely used in aerospace and other industries due to its high strength, corrosion resistance and ability to retain strength at high temperatures. It is
This document provides an overview of numerical control and computer numerical control systems. It discusses the need for NC/CNC, the advantages and disadvantages, classifications of NC machines, and components of NC systems such as driving devices, feedback devices, dimensioning systems, and interpolation methods. Key points covered include the history of NC development, the difference between open-loop and closed-loop control, and explanations of incremental and absolute positioning systems.
Nest Institute of NDT posse’s high quality international standard training for NDT in accordance with quality management system and pursuing placement for candidates to improve their career.
To give quality training and education along with placement for the youngsters to enrich their career (or) to make their life delightful.Courses: VISUAL TESTING, LIQUID PENETRANT TESTING, MAGNETIC PARTICLE TESTING, RADIOGRAPHY TESTING, ULTRASONIC TESTING,More Information Visit Our Website nestndt.com
Theory of metal cutting MG University(S8 Production Notes)Denny John
Theory of metal cutting MG University(S8 Production Notes)
Scenario of manufacturing process – Deformation of metals,
Schmid’s law (review only) – Performance and process parameters – single point cutting
tool nomenclature - attributes of each tool nomenclature - attributes of feed and tool
signature on surface roughness obtainable, role of surface roughness on crack initiation -
Oblique and orthogonal cutting – Mechanism of metal removal - Primary and secondary
deformation shear zones - Mechanism of chip formation, card model, types of chip,
curling of chips, flow lines in a chip, BUE, chip breakers, chip thickness ratio –
Mechanism of orthogonal cutting: Thin zone and thick zone, Merchant’s analysis – shear
angle relationship, Lee and Shaffer`s relationship, simple problems – Friction process in
metal cutting: nature of sliding friction, columb`s law, adhesion theory, ploughing, sublayer
flow – Empirical determination of force component.
this pdf consist of notes required for non destructive testing..
1. VISUAL INSPECTION
2. LIQUID PENETRANT TESTING
3. MAGNETIC PARTICLE TESTING
4. RADIOGRAPHIC TESTING
5. ULTRASONIC TESTING
6. EDDY CURRENT TESTING
7. THERMOGRAPHIC TESTING
The document discusses recent advances in all-ceramic dental materials. It describes the evolution of ceramics from early dentures to modern machinable ceramics and lists various classification systems. Key points include methods to strengthen porcelain like thermal tempering and transformation toughening, as well as minimizing stress through design. Specific ceramic systems are outlined, like aluminous core porcelain developed by McLean and Hughes in 1965 and In-Ceram, which uses a slip-casting technique to form green ceramic shapes.
The document describes the optimization of brake disc geometry for a vehicle. It aims to minimize disc volume while meeting constraints on stress, natural frequency, and temperature during emergency braking. Finite element analysis is performed in ANSYS to analyze structural stress, vibration modes, and thermal loads. Design of experiments and response surface models are developed in MATLAB to optimize disc inner radius, outer radius, and thickness. Single-objective and multi-objective optimizations are conducted to determine optimal geometries under different load cases.
The document is a capstone project report on studying and analyzing tube failure in water tube boilers. It discusses boiler tube mechanisms, including the purpose of boiler tubes in carrying steam, water, and facilitating steam generation. It then covers a literature review on previous studies of boiler tube failure analysis, design and analysis, thermal analysis, fluid flow analysis, and structural analysis. The report outlines the objectives, scope and methodology of analyzing boiler tube failure through CAD modeling, mathematical modeling using ANSYS, and validating the results. It analyzes thermal, fluid flow and structural behavior of the boiler tube under different operating conditions to determine safe, risky and failure states. The study aims to reduce boiler tube failures by understanding failure causes and providing suitable design remedies
This document presents a final report for a single machine scheduling problem with sequence dependent setup times at an aluminum powder coating plant. The report begins with background on the company, Wispeco Aluminum, which has been producing aluminum extrusion and powder coating since the 1920s. It then describes the project aim to develop an optimization model to improve scheduling at the plant. The report includes a literature review on single machine scheduling and heuristic techniques, an analysis of the current scheduling problem and plant data, the development of a conceptual model and genetic algorithm based solution model in MATLAB, testing and validation of the solution model, and proposed improvements and applications for the plant.
This document summarizes a doctoral thesis that investigates argon bubble behavior in slide-gate nozzles during the continuous casting of steel slabs. Water model experiments were performed to study bubble formation and size under different conditions. An analytical model was developed to predict average bubble size, estimating argon bubbles in steel would be 1-5mm. A 3D finite difference model simulated two-phase flow in nozzles, validated against water experiments. Parametric studies examined the effects of gas injection, casting speed, and nozzle design on flow patterns. An inverse model related nozzle pressure to clogging, argon flow, casting speed, and other operational factors, validated by plant measurements. Suggestions for optimizing argon injection
Study and Analysis of Tube Failure in Water Tube boilerArunMalanthara
This report explain about Study and Analysis of Tube failure in water tube boiler. It tells about safe conditions to prevent accident. Different Mathematical modelling, Design, Thermal analysis, Structural analysis and Pressure analysis have been carried out to get optimum safe conditions.
This document discusses modeling a hot compression test using finite element analysis in ABAQUS. It describes:
1) Creating parts for the deformable bulk material and rigid press and assembling them, defining materials, contacts, steps, and meshing.
2) Developing a viscoplastic constitutive model and implementing it in ABAQUS through user subroutines UMAT and VUMAT.
3) Running a simulation of hot plain strain compression of copper and comparing results from UMAT and VUMAT.
FE Analysis for Investment Casting and Computer Simulation: A Reviewijsrd.com
In the present paper a review for the experimental and finite element analysis techniques is adopted for Investment casting. Experimental Data taken for Solidification of investment Casting is modeled and meshed initially then validation is followed by comparing the experimental and modeled results. This helps to optimize the design criteria for investment casting. To overcome the problem of current gating /riser system and by comparing simulation results of optimized casting model with that of original model we can reduce the shrinkage porosity.
The document discusses the design of a simulant solution to model the non-Newtonian viscosity behavior of coatings. Various combinations of clay and polyethylene glycol (PEG) in water were tested. A solution of 2.2% clay and 0.25% PEG with a cure time of 64 hours was found to best match the target non-Newtonian behavior, falling within the desired ranges for consistency index (m value) and recovery gap (R value). The simulant solution aims to replicate the shear thinning and thixotropic properties of coatings to enable further mixing studies.
This document is a semester thesis submitted by Jesús Ignacio Maldonado Covarrubias to ETH Zurich in June 2011. The thesis investigates the dimensioning of an access panel for the fixed leading edge of a commercial aircraft. The objectives are to analyze an initial access panel design using finite element analysis, evaluate it against criteria such as strength and stability, and perform optimizations to reduce the panel's mass. The work is broken down into tasks such as creating CAD and FE models, analyzing different stiffener configurations, and conducting a design improvement study. The document outlines the problem definition, reviews relevant literature, describes the analytical and FE modeling approaches, and presents the results and conclusions of the study.
The motivation behind the project and research is to present a new characteristic for temperature profile estimation in modelling of Rotary Friction Welding Process. For the first time, a unified model has been exhibited, with an implementation of phase transformation of similar and dissimilar materials and plastics too. The model was generated on ANSYS 15.0, thermal and structural modules were used to plot the temperature curve with which I make a compression. The curve for welding of dissimilar metals was analyzed with that of practical curves already acquired and then the effect of varying parameters on the welding of similar metals was studied.
The document provides installation instructions for DEFORMTM 3D Version 6.1 software. It notes an important change in the password location and details how to install the security key device and DEFORMTM program files. The instructions outline accepting license agreements, selecting installation directories, and rebooting to complete the process. Users are directed to contact support for any installation questions or problems.
Simulation of the Surface Hardening of a Forged CrankshaftGeonx
Adhish Majumdar of GEONX delivered on 18th May 2016 a presentation on the "Simulation of the Surface Hardening of a Forged Crankshaft using High Performance Computing" at the second edition of the ICOMP conference held at Liège, Belgium.
This document is the user manual for DEFORM 3D Version 6.0, a software for analyzing manufacturing processes. It provides an overview of DEFORM's capabilities for simulating metal forming processes, as well as descriptions of the pre-processor for setting up simulations, defining objects and materials, generating meshes, and applying boundary and initial conditions. It also covers using the post-processor to view results and running simulations in interactive or batch modes.
Computer Aided Process Planning (CAPP): concepts; traditional and CAPP; automated
process planning: process planning, general methodology of group technology, code
structures of variant and generative process planning methods, AI in process planning,
process planning software.
Flexible Manufacturing Systems (FMS): Introduction, types, concepts, need and
advantages of FMS - cellular and FMS - JIT and GT applied to FMS.
Optimisation of machining parameters for slot milling operation in Inconel 62...Denny John
Vikram Sarabhai Space Centre (VSSC) is the lead centre for development of satellite launch vehicles and technologies in India. It was established in 1963 as Thumba Equatorial Rocket Launching Station and renamed after Dr. Vikram Sarabhai in 1971. VSSC's major programmes include Polar Satellite Launch Vehicle (PSLV), Geosynchronous Satellite Launch Vehicle (GSLV), and it has made significant contributions to India's space programmes, including the Chandrayaan-1 mission to the moon.
Inconel 625 is a nickel-based super alloy widely used in aerospace and other industries due to its high strength, corrosion resistance and ability to retain strength at high temperatures. It is
This document provides an overview of numerical control and computer numerical control systems. It discusses the need for NC/CNC, the advantages and disadvantages, classifications of NC machines, and components of NC systems such as driving devices, feedback devices, dimensioning systems, and interpolation methods. Key points covered include the history of NC development, the difference between open-loop and closed-loop control, and explanations of incremental and absolute positioning systems.
Nest Institute of NDT posse’s high quality international standard training for NDT in accordance with quality management system and pursuing placement for candidates to improve their career.
To give quality training and education along with placement for the youngsters to enrich their career (or) to make their life delightful.Courses: VISUAL TESTING, LIQUID PENETRANT TESTING, MAGNETIC PARTICLE TESTING, RADIOGRAPHY TESTING, ULTRASONIC TESTING,More Information Visit Our Website nestndt.com
Theory of metal cutting MG University(S8 Production Notes)Denny John
Theory of metal cutting MG University(S8 Production Notes)
Scenario of manufacturing process – Deformation of metals,
Schmid’s law (review only) – Performance and process parameters – single point cutting
tool nomenclature - attributes of each tool nomenclature - attributes of feed and tool
signature on surface roughness obtainable, role of surface roughness on crack initiation -
Oblique and orthogonal cutting – Mechanism of metal removal - Primary and secondary
deformation shear zones - Mechanism of chip formation, card model, types of chip,
curling of chips, flow lines in a chip, BUE, chip breakers, chip thickness ratio –
Mechanism of orthogonal cutting: Thin zone and thick zone, Merchant’s analysis – shear
angle relationship, Lee and Shaffer`s relationship, simple problems – Friction process in
metal cutting: nature of sliding friction, columb`s law, adhesion theory, ploughing, sublayer
flow – Empirical determination of force component.
this pdf consist of notes required for non destructive testing..
1. VISUAL INSPECTION
2. LIQUID PENETRANT TESTING
3. MAGNETIC PARTICLE TESTING
4. RADIOGRAPHIC TESTING
5. ULTRASONIC TESTING
6. EDDY CURRENT TESTING
7. THERMOGRAPHIC TESTING
The document discusses recent advances in all-ceramic dental materials. It describes the evolution of ceramics from early dentures to modern machinable ceramics and lists various classification systems. Key points include methods to strengthen porcelain like thermal tempering and transformation toughening, as well as minimizing stress through design. Specific ceramic systems are outlined, like aluminous core porcelain developed by McLean and Hughes in 1965 and In-Ceram, which uses a slip-casting technique to form green ceramic shapes.
The document describes the optimization of brake disc geometry for a vehicle. It aims to minimize disc volume while meeting constraints on stress, natural frequency, and temperature during emergency braking. Finite element analysis is performed in ANSYS to analyze structural stress, vibration modes, and thermal loads. Design of experiments and response surface models are developed in MATLAB to optimize disc inner radius, outer radius, and thickness. Single-objective and multi-objective optimizations are conducted to determine optimal geometries under different load cases.
The document is a capstone project report on studying and analyzing tube failure in water tube boilers. It discusses boiler tube mechanisms, including the purpose of boiler tubes in carrying steam, water, and facilitating steam generation. It then covers a literature review on previous studies of boiler tube failure analysis, design and analysis, thermal analysis, fluid flow analysis, and structural analysis. The report outlines the objectives, scope and methodology of analyzing boiler tube failure through CAD modeling, mathematical modeling using ANSYS, and validating the results. It analyzes thermal, fluid flow and structural behavior of the boiler tube under different operating conditions to determine safe, risky and failure states. The study aims to reduce boiler tube failures by understanding failure causes and providing suitable design remedies
This document presents a final report for a single machine scheduling problem with sequence dependent setup times at an aluminum powder coating plant. The report begins with background on the company, Wispeco Aluminum, which has been producing aluminum extrusion and powder coating since the 1920s. It then describes the project aim to develop an optimization model to improve scheduling at the plant. The report includes a literature review on single machine scheduling and heuristic techniques, an analysis of the current scheduling problem and plant data, the development of a conceptual model and genetic algorithm based solution model in MATLAB, testing and validation of the solution model, and proposed improvements and applications for the plant.
This document summarizes a doctoral thesis that investigates argon bubble behavior in slide-gate nozzles during the continuous casting of steel slabs. Water model experiments were performed to study bubble formation and size under different conditions. An analytical model was developed to predict average bubble size, estimating argon bubbles in steel would be 1-5mm. A 3D finite difference model simulated two-phase flow in nozzles, validated against water experiments. Parametric studies examined the effects of gas injection, casting speed, and nozzle design on flow patterns. An inverse model related nozzle pressure to clogging, argon flow, casting speed, and other operational factors, validated by plant measurements. Suggestions for optimizing argon injection
Study and Analysis of Tube Failure in Water Tube boilerArunMalanthara
This report explain about Study and Analysis of Tube failure in water tube boiler. It tells about safe conditions to prevent accident. Different Mathematical modelling, Design, Thermal analysis, Structural analysis and Pressure analysis have been carried out to get optimum safe conditions.
This document discusses modeling a hot compression test using finite element analysis in ABAQUS. It describes:
1) Creating parts for the deformable bulk material and rigid press and assembling them, defining materials, contacts, steps, and meshing.
2) Developing a viscoplastic constitutive model and implementing it in ABAQUS through user subroutines UMAT and VUMAT.
3) Running a simulation of hot plain strain compression of copper and comparing results from UMAT and VUMAT.
FE Analysis for Investment Casting and Computer Simulation: A Reviewijsrd.com
In the present paper a review for the experimental and finite element analysis techniques is adopted for Investment casting. Experimental Data taken for Solidification of investment Casting is modeled and meshed initially then validation is followed by comparing the experimental and modeled results. This helps to optimize the design criteria for investment casting. To overcome the problem of current gating /riser system and by comparing simulation results of optimized casting model with that of original model we can reduce the shrinkage porosity.
The document discusses the design of a simulant solution to model the non-Newtonian viscosity behavior of coatings. Various combinations of clay and polyethylene glycol (PEG) in water were tested. A solution of 2.2% clay and 0.25% PEG with a cure time of 64 hours was found to best match the target non-Newtonian behavior, falling within the desired ranges for consistency index (m value) and recovery gap (R value). The simulant solution aims to replicate the shear thinning and thixotropic properties of coatings to enable further mixing studies.
This document is a semester thesis submitted by Jesús Ignacio Maldonado Covarrubias to ETH Zurich in June 2011. The thesis investigates the dimensioning of an access panel for the fixed leading edge of a commercial aircraft. The objectives are to analyze an initial access panel design using finite element analysis, evaluate it against criteria such as strength and stability, and perform optimizations to reduce the panel's mass. The work is broken down into tasks such as creating CAD and FE models, analyzing different stiffener configurations, and conducting a design improvement study. The document outlines the problem definition, reviews relevant literature, describes the analytical and FE modeling approaches, and presents the results and conclusions of the study.
The motivation behind the project and research is to present a new characteristic for temperature profile estimation in modelling of Rotary Friction Welding Process. For the first time, a unified model has been exhibited, with an implementation of phase transformation of similar and dissimilar materials and plastics too. The model was generated on ANSYS 15.0, thermal and structural modules were used to plot the temperature curve with which I make a compression. The curve for welding of dissimilar metals was analyzed with that of practical curves already acquired and then the effect of varying parameters on the welding of similar metals was studied.
This document summarizes a project report on analyzing air flow in a single cylinder four-stroke engine using computational fluid dynamics (CFD). The project involves 3D modeling of the engine cylinder in CREO and meshing in ANSYS GAMBIT. CFD simulations are performed using STAR-CD to analyze air flow for inlet manifold angles of 30 and 90 degrees. Post-processing of velocity vector diagrams, air particle motion diagrams, and kinetic energy plots from STAR-CD are used to determine the optimized inlet manifold design that provides better swirl motion within the engine cylinder.
Marine transport is a critical means of moving people and goods around the littoral waters of Southeast
Alaska. Unfortunately, it also generates significant harmful emissions. Tidelines Institute, a Southeast
AK-based leader in environmental education and research, requires a more environmentally friendly
propulsion system for their vessel, Tara. This project designed a serial hybrid propulsion system for
Tara, furnishing Tidelines with a bill of materials, design documentation, implementation diagrams, CAD
drawings, operational analysis software, and a life cycle assessment. This design will take advantage of
the substantial hydro power resources in the region and help Tidelines be an agent of structural change.
Design and Optimization of Knuckle Joint Using TrussesAbdul Farhan
This document is a seminar report submitted by Abdul Farhan to fulfill the requirements for a Bachelor of Engineering degree in Mechanical Engineering. The report discusses the design and optimization of a knuckle joint using trusses. It begins with an introduction to knuckle joints, their components and applications. A literature survey is then presented summarizing previous research on knuckle joint design. The report goes on to describe the design of a baseline knuckle joint model and several modified models incorporating truss structures. The models are analyzed using finite element analysis software to evaluate factors like stress distribution, deformation and weight. The results are compared and discussed to determine the optimal truss design for the knuckle joint.
Asu December 2010 Application For Bio Pcmenergy4you
This thesis examines the application of phase change material (PCM) in buildings for energy conservation. Experimental testing was conducted on a shed incorporating an organic-based PCM called BioPCM into the envelope. EnergyPlus simulations were performed to validate the experimental results. The simulation yielded comparable energy consumption trends to the experimental data but did not capture the peak load time shifts observed. Parametric studies in the simulation examined factors like PCM thermal conductivity, temperature range, location, insulation, and combinations of multiple PCMs. It was found that a PCM with a melting point of 23-27°C led to maximum energy savings and peak load shift for the building in Phoenix, Arizona.
This document presents the design and analysis of a scramjet engine. The author uses quasi-one-dimensional equations to model the compressible flow and combustion within the engine. Performance is estimated using computational modeling of the inlet, combustor, and nozzle. Initial results show a thrust of nearly 405 kN and specific impulse of 174 seconds. Further analysis of the combustion chamber and boundary layers is recommended.
This document provides an overview of a book on finite element modeling of machining processes. It includes 5 chapters that discuss machining processes and chip formation, analytical modeling techniques, finite element modeling considerations and methodology, applications of finite element modeling to specific machining processes like high speed and micro machining, and other modeling techniques such as modeling of grinding and use of soft computing and molecular dynamics. It aims to introduce readers to modeling of machining using finite element analysis and provide examples of its applications.
This document is a project report submitted by four students for their Bachelor of Engineering degree in Mechanical Engineering. The report details the design of a novel MEMS-based acoustic filter for gunshot detection. It includes an introduction, literature review on relevant MEMS fabrication techniques, numerical analysis of the designed diaphragm, manufacturing details, testing procedures, and plans for future work. The students designed and fabricated a prototype MEMS acoustic sensor, tested it to detect gunshots, and analyzed the sensor's performance through numerical simulation and experimentation.
In this project we studied dynamic loading behaviour of different models of portal frame which are subjected to moving mass on top of horizontal beam. A finite element simulation has been carried out in order to study the behaviour of a transverse open crack in the horizontal segment of a portal frame while it is subjected to a moving mass. This portal frame is hinged to the ground and only in-plane vibrations are considered. The horizontal section is modelled as two segments connected by a rotational mass-less linear elastic spring. Portal frames are modelled using the C-coding. The characteristic equation is obtained with due consideration towards boundary and compatibility conditions. The resulting characteristic equation is a function of the frames natural frequency, crack location and crack depth. The frequency values are used to decide the appropriate time step for the dynamic analysis. The finite element modelling has been done with singular quadratic quadrilateral planar elements. Results are mainly used to calculate crack opening, crack closing and crack growth rate time. Various conclusive inferences have been made from the results obtained. The output solutions such as stress, strain and displacement was studied and discussed.
The document describes a numerical simulation of flow through a centrifugal pump impeller. Hassan Adel Talaat El-Sheshtawy conducted 3D CFD simulations using ANSYS/CFX to analyze the flow field and evaluate the slip factor. The simulation results agreed well with the design performance curve, especially near the best efficiency point. Several empirical slip factor correlations were compared to the numerically obtained slip factor. The effects of adding splitters and increasing the number of blades on slip factor, head rise and hydraulic efficiency were also investigated. It was found that while slip factor improved with more blades or longer splitters, hydraulic efficiency did not always increase due to additional losses.
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SIMULATION AND OPTIMIZATION OF MATERIAL FLOW FORGING DEFECTS IN AUTOMOBILE COMPONENT AND REMEDIAL MEASURES USING DEFORM SOFTWARE
1. SIMULATION AND OPTIMIZATION OF MATERIAL FLOW
FORGING DEFECTS IN AUTOMOBILE COMPONENT AND
REMEDIAL MEASURES USING DEFORM SOFTWARE
SEMINAR REPORT
Submitted by
BENJI MATHEW VARGHESE
REGISTER NO: 11003326
DEPARTMENT OF MECHANICAL ENGINEERING
Believers Church
Caarmel Engineering College
R-Perunad, Pathanamthitta – 689 711
MAHATMA GANDHI UUNNIIVVEERRSSIITTYY
KOTTAYAM - 686 560
NOVEMBER 2014
2. Seminar guide
Noble John Philip
Asst. Professor
Dept. of Mechanical Engg.
Caarmel Engineering College
R - Perunad
Co-ordinator
Shan James/Arun G Nath
Asst. Professor
Dept. of Mechanical Engg.
Caarmel Engineering College
R - Perunad
Head of the Department
Prof. Pramod George
Assoc. Professor
Dept. of Mechanical Engg.
Caarmel Engineering College
R - Perunad
CERTIFICATE
This is to certify that this seminar entitled
SIMULATION AND OPTIMIZATION OF MATERIAL
FLOW FORGING DEFECTS IN AUTOMOBILE COMPONENT
AND REMEDIAL MEASURES USING DEFORM SOFTWARE
was presented by
BENJI MATHEW VARGHESE
during the year 2014 in partial fulfillment of the requirement for the
award of Degree of Bachelor of Technology in Mechanical Engineering
by the
Mahatma Gandhi University.
3. i
ACKNOWLEDGEMENT
First of all, I thank the Almighty God for providing me the strength and courage to
present the seminar successfully.
I express my gratitude towards our Principal, Dr. Paul A.J. and the management of
our college for their support.
I use this opportunity to express my sincere gratitude towards Assoc. Prof. Pramod
George, Head of the Department of Mechanical Engineering for his valuable support,
inspiring assistance, encouragement and useful guidance. I would also like to thank Asst.
Prof. Shan James and Asst. Prof. Arun G. Nath for their valuable opinions and
corrections. I also thank my seminar guide Asst. Prof. Noble John Philip for his guidance,
support and assistance for doing my seminar in a systematic manner.
Last, but not the least, I wish to express my sincere thanks to all my friends for their
goodwill and constructive ideas and also my parents for their moral support.
4. ii
ABSTRACT
There are many types of defects like pitting, cracks, folds or laps, unfilling and size
variations prevalent in forging process. This paper presents the analyses of material flow
related defects with the aim of solving them using DEFORM 3D software. The main focus
is on the positioning of the billet to be kept on the bottom die and its temperature limit to
prevent the defects. A range for the positioning of the billet and temperature limit is
proposed and it is found that if the billet is kept beyond that limit, it showed the defects of
unfilling. The research is conducted on a ST 52/3 steel End plate used in automobiles, and
the results of the simulation are correlated with the Statistical results.
Key Words: DEFORM 3D, ST 52/3 Steel, Material flow, End Plate
5. iii
CONTENTS
Acknowledgement……………………………...……………………………………….…...i
Abstract……………………………………………………………………………………...ii
List of tables................……………………………………………………………………...iv
List of figues...........................................................................................................................v
Abbreviations……..……………………………………………………………………...…vi
Chapter 1 Introduction………………………………………………………………….…...1
Chapter 2 Problem description……………………………………………………………....3
Chapter 3 Literature review………………………………………………….……….……..4
Chapter 4 Methodology.................................................................................................….....5
Chapter 5 Numerical Simulation.............................................................................................7
5.1 DEFORM 3D Software...................................................................................…...7
5.2 Simulation of the forging of end plate....................................................................8
Chapter 6 Results and discussions......................................................…………………......10
6.1 Deform 3d simulation results............................................................…….…........10
6.1.1 Simulation results based on the change in position of workpiece..............10
6.1.2 Simulation results based on different temperatures...................................13
6.1.3 Design of experiment results...............................................….……....….14
Chapter 7 Advantages...........................……………….…………………………………..18
Chapter 8 Conclusions……………………………………………………………………..19
References………………………………………….………………………………...….…20
6. iv
LIST OF TABLES
Table 6.1 Results of simulation based on positioning of the workpiece on the bottom die
during forging process……......................................................................……….12
Table 6.2 Results of simulation based on different temperature of the workpiece on the
bottom die during forging process ......................................................................14
Table 6.3 Different levels of the operating parameters (X & Y) ........................................14
Table 6.4 Set of combination of these parameters at which different experiments are
performed.............................................................................................................14
Table 6.5 ANOVA results of Design of Experiments.............................................................15
Table 6.6 Values of regression coefficients calculated from MATLAB............................16
7. v
LIST OF FIGURES
Figure 4.1 Methodology of the process ........................…...……………………………......5
Figure 5.1 Simulation of the forging process..................................................……………...7
Figure 5.2 Meshing of the billet............................….............................................................7
Figure 5.3 End Plate...............................................................................................................8
Figure 5.4 Simulation of End Plate …..……………………………………….………...….8
Figure 6.1 Simulation of the end plate within the Range (X= -195mm, Y=170mm) ...........10
Figure 6.2 Simulation of the end plate Range (X= -195mm, Y=175mm)..............................10
Figure 6.3 Simulation of the end plate within the Range (X= -190mm, Y=170mm)............11
Figure 6.4 Simulation of the end plate Range (X= -190mm, Y=175mm) ............................11
Figure 6.5 Simulation of the end plate within the Range (X= -190mm, Y=180mm.............11
Figure 6.6 Simulation of the end plate within Range (X= -185mm, Y=175mm).................11
Figure 6.7 Simulation of the end plate beyond the Range (X= -190mm, Y=180mm) .........12
Figure 6.8 Simulation of the end plate Range (X= -185mm, Y=175mm).............................12
Figure 6.9 Simulation of end plate at 1200 °C ....................................................................13
Figure 6.10 Simulation of end plate at 1000°C ....................................................................13
Figure 6.11 Simulation of end plate at 900 °C .....................................................................13
Figure 6.12 Comparison of results of simulation and Mathematical Model .............................17
8. vi
ABBREVIATIONS
FEM - Finite Element Method
ANOVA - Analysis of Variance
STL - STereoLithography
AISI - American Iron and Steel Institute
9. CHAPTER 1
INTRODUCTION
The process of forging is concerned with the shaping of metals by the application of
compressive forces. Forging is often classified according to the temperature at which it is
performed: '"cold," "warm," or "hot" forging. Forged parts can range in weight from less than
a kilogram to 170 metric tons. Forged parts usually require further processing to achieve a
finished part. The main advantage of hot forging is that as the metal is deformed work
hardening effects are negated by the recrystallization process. Forged parts are stronger and
tougher than cast or machined parts made from the same material due to the reason that the
hammering process arranges the micro-structure of the metal so that the crystal grains get
aligned along the part profile.
Usually, the shapes of components manufactured by forging are complex; and many
defects are induced during the process of forging such as: under filling, laps and folds.
In the past, the problems were solved by seasoned technician with trial and error.
Nowadays, the finite element method (FEM) has proven its efficiency and usefulness
simulating steady and non-steady metal forming processes. Following the development of
computer technology, the commercial based forging analysis software is gradually perfect.
An algorithm for optimal design of non-isothermal metal forming processes has been
presented. The methodology is applied to optimize the preform die shape in two-stage
forging and the initial temperature of the work-piece. The authors have analyzed the changes
of structure and temperature field in process of crankshaft forging, and the rules of metal
flow are summarized, the defects formation and preventive actions were analyzed, and the
shape of blank was optimized. The authors have discussed that the forging analysis model
can minimize the testing requirements.The authors have summarized the distribution of
strains in the various regions of the part. This has been shown that friction and lubrication
increases the amount of load required in the forging process. The authors have been able to
analyze the material flow of a forging component using DEFORM™-2D. This has been
shown that the material yield can be increased by developing a flash less version of the
component using DEFORM-2D. Simulation of stresses, strains and temperature at different
regions have also been done for defect analysis Simple model for heat transfer coefficient
between work piece and dies have also been developed. Authors have also used MSC Super
10. Forge for simulation of the forging process .
Various authors have discussed about various factors related with FE techniques used
for forging process. However, the issues related with positioning of the billet on the bottom
die and the temperature limit for billet are not being addressed. The aim of this research is the
analysis of the material flow defects like unfilling by taking into consideration, the above
stated issues. This research would be beneficial in reducing the material flow defects.
11. CHAPTER 2
PROBLEM DESCRIPTION
Many types of defects like pitting, cracks, folds or laps, unfilling and size variations
prevalent in forging process. This defects can cause the product to be unfit for use. The defect
formation cannot be avoided but can be decreased by taking proper care and measurements.
As it is said prevention is better than cure, so conducting a simulation of the flow of
the material we can analyze the properties of the material and accordingly measures can be
made for improving its flow and also to avoid defects. One such method is of place a billet at
bottom portions which decrease the temperature formed due to direct flow on to the bottom.
Thus by doing this we can avoid the defects happening.
In the past, the forging defect analysis were done by skilled technician with trial and
error method. The main disadvantages of this method are different experiments have to be
performed huge material loss, large time consumption and increases cost. Finite element
softwares are used to rectify above problems.
12. CHAPTER 3
LITERATURE REVIEW
Zhang Z., Dai G., Wu S., Dong L., and Liu L have discussed about various factors
related with FE techniques used for forging process. However, the issues related with
positioning of the billet on the bottom die and the temperature limit for billet are not being
addressed. The aim of this research is the analysis of the material flow defects like unfilling
by taking into consideration, the above stated issues. This research would be beneficial in
reducing the material flow forging defects.
A.M. Jafarpour, A.S. Asl, R. Bihamta, have discussed about various factors related
with FE techniques used for forging process. However, the issues related with positioning of
the billet on the bottom die and the temperature limit for billet are not being addressed. The
aim of this research is the analysis of the material flow defects like unfilling by taking into
consideration, the above stated issues. This research would be beneficial in reducing the
material flow defects.
Carlos C. Antonio, Catarina F. Castro, Luisa C. Sousa, have discussed that the forging
analysis model can minimize the testing requirements and they have summarized the
distribution of strains in the various regions of the part. This has been shown that friction and
lubrication increases the amount of load required in the forging process.
13. CHAPTER 4
METHODOLOGY
Modelling of dies in Pro-e software
Importing the modeled drawings into
DEFORM 3D software in .STL
Setting of all the input parameters
in the pre -processor module of
DEFORM 3D software.
Positioning of the billet on the
bottom die
Starting the simulation in the
Simulator module
Checking the simulation for
uniformity of material flow by giving
a pause to the simulation.
No
Is material flow
uniform?
Yes
A
Continue Simulation
Viewing of results in the
post-processor module of
DEFORM 3D software
Fig. 4.1 Methodology of the process
14. This begins with the modeling of the dies in the 3D modelling software Pro-e. The
modelled drawings are then imported in .STL format in DEFORM 3D software. The dies are
imported in the preprocessor module of DEFORM 3D software. In this module all the input
parameters are provided. These input parameters include the material of the workpiece and
the dies, object meshing, temperature range, friction coefficient, positioning of the
workpiece. After inputting all the parameters, the simulation is started in the simulator
module. The simulation can be paused in between and we can check whether the material
flow is uniform in the die cavity or not. The results of the simulation are viewed in the post
processor module of the software. Figure 4.1 shows the methodology followed in this
process. Deform software also gives an option for fast solution processing. This product is a
well-tested, industrial simulation engine with an interface that allows the user to make use of
it to the fullest potential.
15. CHAPTER 5
NUMERICAL SIMULATION
5.1 DEFORM 3D SOFTWARE
The forging process generally consists of heating the billet material to a specific
temperature after which it is deformed plastically into certain shapes by applying
compressive force on the work piece (billet). At the end of the deformation process, the shape
of the die is acquired by the work piece and a desired geometry is obtained. This research
tests the forging ability of 3D Forming software package called DEFORM 3D package.
The forging problem analyzed in this paper is that of a ST 52/3 steel end plate which is used
in automobile axles. In this paper various defects occurring in forging due to material flow
like laps, unfilling are analyzed with the help of simulation using DEFORM
TM
3D Version
6.1.
Figure 5.1 shows the simulation of the forging process on a cylindrical billet and Figure 5.2
shows the meshing of the billet. The meshing of the billet is done by the software into 12000
elements.
Fig. 5.1 Simulation of the forging process Fig. 5.2 Meshing of the billet
16. 5.2 SIMULATION OF THE FORGING OF END PLATE
As mentioned earlier, the process analyzed is that of an actual industrial production
forging. This problem was provided by R.B. Forgings Pvt. Ltd. Punjab India. The defects are
analyzed using an End Plate used in the axles of automobiles. Figure 5.3 shows the original
end plate and Figure 5.4 shows the simulation of the end plate.
Fig. 5.3 End Plate Fig. 5.4 Simulation of End Plate
The defect analysis of the end plate is done by performing a number of simulations on the
HOT FORGING option in the software package DEFORM 3D v6.1 SP1.
Different Simulations are carried out using different orientations (rotational and
offset) of the work piece and optimization of the work piece is done by these simulations.
The Simulations are carried out on the basis of change in position of the workpiece and the
change in temperature of the workpiece. The logic behind the change in the position of the
workpiece is that, there is a proper range of the Position along X-axis and Position along Y-
axis (in mm) of the workpiece (initially to be kept between the dies). If the workpiece is kept
beyond that range, then the defect of partial unfilling of the final component will occur.
Different Simulations are also carried out at different temperatures (900°C, 1000°C,
and 1200°C.) The objective of these simulations is to check for the optimum temperature for
the forging process of this component. Before starting the forging process, the raw material
17. (billets) is kept in the furnace at 1200 °C for about one hour. Now if the billet is not kept in
the furnace for proper time, i.e. if it is taken out of the furnace after 30 or 40 minutes, then
the temperature in the workpiece upto the core does not reach 1200 °C and if the workpiece is
not heated (completely) upto an exact temperature, the material will cool down early during
the forging process and will not properly fill in the die impression. Due to this there will be
the defect of unfilling of the component. Due to the improper flow of the material, more
material will be accumulated as required, at some place in the die cavities and this will create
the final components of oversize. The results obtained by simulations are then validated
statistically using Analysis of Variance in the Statistic module of MATLAB software. A
Mathematical Model using Regression Coefficients is prepared and the results are compared.
18. CHAPTER 6
RESULTS AND DISCUSSIONS
6.1 DEFORM 3D SIMULATION RESULTS
In the DEFORM 3D Software package, the Simulations are done in the Hot Forging
option. The billet taken is cylindrical as used in the industry, and its dimensions are 58 mm
Diameter and 154.5 mm length. The volume of the workpiece is 407507 mm
3
. The billet
material taken is AISI_1016 due to its close resemblance to ST 52/3 (used in industry for this
component).The dies are modeled in Pro-e Modeling software and are imported as STL
format to DEFORM 3D.
6.1.1 SIMULATION RESULTS BASED ON THE CHANGE IN POSITION
OF THE WORKPIECE:
After carrying out many simulations with different positions at which the workpiece
is kept in between the dies, it was found that the complete cavity of the die is filled (i.e.
without defect of unfilling) in the following range:
Position along X-Axis = (-185 to -195 mm) (Translational)
Position along Y-Axis = (170 to 180 mm) (Translational)
The position along Z axis (Translational) and along X-axis (Rotational) and Z-axis
(Rotational) are kept constant as 29mm, 90° and -22° respectively.
Fig. 6.1 Simulation of the end plate within the Fig. 6.2 Simulation of the end plate
Range (X= -195mm, Y=170mm) Range (X= -195mm, Y=175mm)
19. Figure 6.1 to Figure 6.6 shows the results of simulation of the forging when the billet is kept
in the defined range of positioning. These results show the complete filling of the die with
billet material without any defect.
Fig. 6.3 Simulation of the end plate
within the within the Range (X= -190mm,
Y=170mm)
Fig. 6.4 Simulation of the end plate
Range (X= -190mm, Y=175mm)
Fig. 6.5 Simulation of the end plate within
the Range (X= -190mm, Y=180mm)
Fig. 6.6 Simulation of the end plate
within Range (X= -185mm, Y=175mm)
20. Simulations are also carried out by keeping the billet beyond the range defined above.
These simulations showed the defect of unfilling of the component. Figure 6.7 and Figure 6.8
shows the simulation of the forging keeping the billet beyond the range
Fig. 6.7 Simulation of the end plate beyond the Fig. 6.8 Simulation of the end plate
beyond Range (X= -190mm, Y=180mm) Range (X= -185mm, Y=175mm)
Table 6.1 shows the results of simulation based on positioning of the workpiece on
the bottom die during forging process
Position along axis (mm)
S No. Observation
X Y
1. -195 170 Completely Filled
2. -195 175 Completely Filled
3. -190 170 Completely Filled
4. -190 175 Completely Filled
5. -190 180 Completely Filled
6. -185 170 Completely Filled
7. -185 175 Completely Filled
8. -185 180 Completely Filled
9. -175 165 Partially Unfilled
10. -200 165 Partially Unfilled
21. 6.1.2 SIMULATIONS RESULTS BASED ON THE DIFFERENT TEMPERATURES
Simulations are carried out at different temperatures (1200°C, 1000°C, 900°C),
keeping the other parameters constant and variations in the output are noticed. Figure 6.9
shows the simulation of the end plate at 1200 °C, the result is completely filled forging.
Figure 6.10 and 6.11 shows the unfilled components when the simulation was carried out at
1000 °C and 900 °C respectively.
Fig. 6.9 Simulation of end plate at 1200 °C
Fig. 6.10 Simulation of end plate at 1000 °C Fig. 6.11 Simulation of end plate at 900 °C
22. S No. Temperature (°C) Observations
1. 1200 Completely Filled
2. 1000 Partially Unfilled
3. 900 Partially Unfilled
Table 6.2 shows the results of simulation based on different temperature of the workpiece
on the bottom die during forging process.
6.1.3 DESIGN OF EXPERIMENTS RESULTS
F-test is based on F-distributions and is used to compare the variance of two
independent samples or factors. This test is also used in the context of Analysis of Variance
(ANOVA) for judging the significance of multiple correlation coefficients. [4]
The operating variables considered in this experiment are Position along X axis (X) and
Position along Y axis (Y). The output variable is the scrap volume. With each set of
combinations of the operating parameters the resultant volume changes. Here we will
optimize the output scrap volume. The scrap volume is calculated by subtracting the volume
of the final component (end plate after trimming) from the total volume (i.e. volume of the
end plate including that of the flash)
Table 6.3 shows the different levels of the operating parameters (X & Y)
Table 6.4 shows the set of combination of these parameters at which different experiments
are performed.
Parameters Level 1 Level 2 Level 3
X (mm) -195 -190 -185
Y (mm) 170 175 180
S No. Combinations of Parameters
X (mm) Y (mm)
1. -195 170
2. -195 175
3. -195 180
4. -190 170
5. -190 175
6. -190 180
7. -185 170
8. -185 175
9. -185 180
23. The values input parameters are input in the MATLAB software and it generated the results
shown in Table 6.5 This ANOVA table gives the percentage contribution of the different
parameters independently and their combined effect and the error.
The results show that the %age contribution of the Position along X-axis is 10.10%,
contribution of Position along Y-axis is 35.10% and the combined contribution of Position
along X-axis and Position along Y-axis is 44.20% with 10.59% error.
Table 6.5 shows the ANOVA results of Design of Experiments
The experimental work done to study the factorial effects is planned in accordance with
the statistical techniques of the experimental design. With a well-designed experiment it is
possible to determine accurately, with a much reduced effort the effect of change in any one
variable of the process output (also known as response or yield) and the interaction effects
between the different factors if any. If all the investigated factors are quantitative in nature,
then it is possible to approximate the response Yu as a polynomial.
The mathematical model is represented in equation number 1 as:
k k
Yu = b0 + Σbi xi + Σbii xi
2
i=1 i=1 + Σb
ij x
i x
j (1)
i < j
S No. Control Sum of Degree of Variance F0 %age of
Factor Squares freedom Contribution
1. A: Position 4.55813*10
7
2 22790700 8.58 10.1040523
along
X-axis
2. B: Position 1.58353*10 2 79176400 29.82 35.1022679
along
Y-axis
3. Interaction 1.99399*10 4 49849700 18.78 44.2009758
4. Error 4.77864*10 18 2654800 10.592859
5. Total 4.51119*10 26 100
24. where Xi (i = 1,2,--------k) are coded levels of K quantitative variables and b0, b1------, etc
are the least square estimates of the regression coefficients. The polynomial is also known as
Regression function and the first term under the summation sign pertains to linear effect, the
second term under the summation sign pertains to quadratic effects, and the third term
pertains to interaction effects of the investigated parameters.
The least square estimator of the regression coefficients is defined by equation 2 as:
B
^
= (X
T
X)
T
X
T
Y (2)
The values of Regression Coefficients are obtained by solving the above
equations in MATLAB software. The values of Regression Coefficients for the
given model are shown in table 6.
Table 6.6 shows the values of regression coefficients calculated from MATLAB
Using the values of regression coefficients, following mathematical model is prepared for
the scrap volume. Then the results of the simulation and that of the mathematical model are
compared for validation and the results relate closely.
Equation 3 represents the mathematical model prepared for this research.
Y = 1.3622*10
4
+ 0.2915*10
4
x1 + 0.1496*10
4
x2 - 0.0952*10
4
x12 + 0.0938*10
4
x22 - 0.2219*10
4
x1x2 (3)
Regression b0 b1 b2 b11 b22 b12
Coefficients
Value 1.3622*10
4
0.2915*10
4
0.1496*10
4
-0.0952*10
4
0.0938*10
4
-0.2219*10
4
25. Following Graph drawn in Microsoft Excel sheet describes the comparison between the
experimental values of scrap volume, calculated by simulations and the values of scrap
volume calculated by the mathematical model.
Fig 6.12 Comparison of results of simulation and Mathematical Model
26. CHAPTER 7
ADVANTAGES
The main advantages of using finite element technique software such as DEFORM
3D for finding out flow forging defects are as follows.
It minimises the testing requirements for the experiments.
As there is no repetition of experiments there is no material losses taking place
and also it saves the time.
By using such softwares the exact positioning for the billet can be defined.
It reduces the experiment cost as there is no wastage of materials.
It is much accurate than that of trial and error methods so which is more
reliable.
27. CHAPTER 8
CONCLUSION
This technique is a step forward in finding a solution to the material flow
related defects in the forging components. There are a lot of defects which are
generally seen in the forging components as described in the earlier sections.
1. In this seminar, the material flow related defects such as under fill,
over sizing of the components has been analyzed.
2. An exact range has been defined for the positioning of the billet in
between the dies. Positioning of the billet plays a very important role
in controlling the unfilling of the component. If the billet is placed
outside this range, the defect of unfilling will occur.
3. Another way of controlling these defects is by checking the proper
temperature of the billet.
Generally, before the forging of the component, the billet is heated at 1200 °C for
about an hour. This is done to heat the billet upto the core so that, when load is applied by the
forging press, the material flows easily inside the die cavity.
The actual effects of the input processes on the forging defects can be calculated. The
use of Finite Element Software like the one used in this research for these practical problems
will save a lot of time and money of the industry. In this software package, a lot of
simulations have been done to reach at a final solution. But in actual practice, if the industry
tries to reach at a optimum solution by performing different experiments on the presses, this
will cost heavily to the industry and will also consume a lot of time.
28. REFERENCE
1. A.M. Jafarpour, A.S. Asl, R. Bihamta, Simulation and Studying of Conical Gears
Forging, Trends in Applied Sciences Research, Academic Journals Inc. (2010)
2. Chris Wheelhouse, Dr Brian Miller, The Industrial Application of Forging Simulation At
UEF Ltd., Confederation of British Metalforming Technical Conference.
3. Deform 3D Manual, DEFORM
TM
3D Version 6.1.
4. Manufacturing Technology by P.N. Rao, Tata McGraw-Hill Publishing Company Ltd.