Sensitivity Analysis of Effect Related with Material Process and Assembly Variations to Loads Deformation and Stress on HSS Stamping Die

During stamping process, the material properties, process design parameters and production environments inevitably have variation and noisy factors, which possibly affect the sheet metal formability and the deformation of the die structure.After gaining a success in applying sheet metal forming numerical simulation analysis to get the forming loads during stamping process, a methodology of die structure analysis based on sheet metal forming simulation was proposed and validated by experiments.Based on these results, the effect related with initial blank thickness, blank holder force, blank positioning error and die alignment error variations to a DP600 hyperbolic bottomed cup drawing die's forming loads(especially unbalanced loads), and deformation and stress was studied numerically.The influence level of these variations to the die's forming loads, deformation and stress was disclosed.The findings can guide die design, die tryout and process control for high-strength steel(HSS) stamping with increased forming load and decreased sheet metal formability.     

三维曲面船体外板成形加工的新方法

国内外船厂通常采用人工操作压力机与水火弯曲相结合的方式进行双曲度船体外板加工,这种方式生产效率低,质量差,环境差,成为造船过程中的瓶颈.文中提出了基于＂方形压头可调活络模具板材曲面成形装置＂的板材成形方法.它通过一组方形压头组成的可调活络模具代替传统的整体模具,实现对板材冲压时压痕及皱折的有效控制.介绍了其组成及工作原理,并通过帆形板、鞍形板成形试验验证了其可行性.     

Dynamic investigation on floating raft with elastic limiters

In this paper, we consider a floating raft isolation system with elastic limiters. The limiters might be “contact” or “no contact”, thus forming a unilateral system generating possible contacts. In order to avoid the large displacement of the floating raft under shock, limiters might be adopted but good limiters design requires the values of the gaps. Based on the contact dynamics, the multi-degree-freedom dynamic model of floating raft isolation system with elastic limiters is established. The artificial neural network has been developed to dingtinguish the contact state of elastic limiters at each step. The example analysis shows that the algorithm of neural network for contact can shorten the time of caclaution. From the example analysis, we get some interesting results that may be useful to the ship engineering.     

Study on Factors Affecting Springback and Application of Data Mining in Springback Analysis

Springback of sheet metal induced by elastic recovery is one of major defects in sheet metal forming processed. Springback is influenced by many factors including properties of the sheet material and processing conditions. In this paper, a springback simulation was conducted and comparisons between the results based on different processing variables were illustrated. The discovery of knowledge of the effects of geometry and process parameters on springback from FEM results becomes increasingly important, as the number of numerical simulation has grown exponentially. Data mining is an effective tool to realize knowledge discovery in simulation results. A datamining algorithm, rough sets theory (RST), was applied to analyze the effects of process parameters on springback in U-bending.     

Numerical Simulation Research on Laser Shock Forming of Thin Metal Sheet

Laser shock forming (LSF) of sheet metal is a new technique realized by applying an impulsive pressure generated by laser-induced shock wave on the surface of metal sheet.LSF of brass sheet metal was investigated using a Q-switched Nd:YAG laser with an energy per pulse of 15～50 joules.ABAQUS software was used to simulate laser shock forming process.The central displacement of the shocked region is measured and compared with the simulation.The higher pulse energy, the higher central displacement of the shocked region were obtained.The deformation of the simulation matches the experiment quite well.     

Dynamic Simulation and Performance Investigation of No-Frost Refrigerator： Part Ⅱ System Simulation and Performance Analysis

The methodology for modeling no-frost refrigerator is described based on the component models developed in Part I, and then, system simulation is applied to a BCD-235W refrigerator-freezer (RF). Experiments are carried out to study “pull-down” and steady-state performance of the RF, and to determine how the experiment and simulation temperature stack up against each other. Good match is found between simulated and measured results for the “pull-down” period. For the steady-state period, the simulation results are also found to agree well with experiment ones except for the temperature profiles of the refrigerator compartment (RC) and freezer compartment (FC). The average temperature and the energy consumption errors between measurement and simulation are less than 10%. Although the model can not reflect the non-uniform air temperature fields in the RC and FC, the variation range and periodicities of the temperature correlate well between the simulation and experiment. We conclude that such a model is valid for investigating the performance of no-frost refrigerator.      

Modeling of additive manufacturing process relevant feature in layer based manufacturing process planning

Compared with general machining processes, additive manufacturing (AM) process has stabler planning route and limited process variables and this makes it to be more easily designed and planned with knowledge based systems and computer aided techniques. Case based reasoning approach is applied to the process planning of additive manufacturing in this paper. The concept of “AM process relevant design features” is proposed after the analysis of the characteristics of AM processes. The concept is used as the basis of the knowledge representation, and AM relevant feature graph is used as the case representation schema. The case retrieval method is discussed based on this graph. The case representation of a machine arm is given to illustrate the brief process of the proposed approach.     

CAE-Based Robust Optimization for Deep-Drawing Process of Sheet Metal Forming Using Grey Relational Analysis Method

The theory of grey systems is a new technique for performing prediction, relational analysis and decision making in many areas. The grey relational analysis was used to optimize the deep-drawing process parameters with considerations of the multiple response (the wrinkle, crack and thinning variation). The deep-drawing parameters, such as the blank holding force (F_ bh ), the radii of punch and die (R_1,R_2), the coefficients of friction (μ_1,μ_2,μ_3) are considered. An orthogonal array is used for the experimental design. The multiple response values are obtained making use of finite element analysis (FEA). Optimal process parameters are determined by the grey relational grade obtained from the grey relational analysis for multi-performance characteristics (the wrinkle, crack and the thinning). The analysis of variance (ANOVA) for the grey relational grade is implemented. The results show that the quality of stamped parts can be improved effectively through the new approach. The grey relational analysis can be applied in sheet metal forming.     

Real-time life-cycle modular design method based on game theory for jack-up

AbstractTo study an entity the entire jack-up performs as a total system with close interdependency and high level of integration of a myriad of subsystems supporting each individual function.All subsystems should be arranged in regular geometric space with clear regional division according to their respective functions.The "building block"such as arrangement makes it feasible to apply modular design method while the integration and conflicts among subsystems offer an arena for game theoretic analysis.All the contradictions between subsystems should be resolved bye the designer.Here we present a game theoretic analysis methodology,which based on the basic principles of game theory,through the establishment of matrix-mode game models to describe and analyze engineering design tasks.By using this method the optimization process in various fields of expertise can be effectively coordinated and controlled,and the parallel design patterns can be achieved to some extent.Taking account of the impact of commercial or technical activities in platform’s life cycle,time line is considered in the early stage of design process which provides more convenience for effcient upgrade and reconfiguration.Some second-hand three-legged jack-up upgrade design process is used as an example to illustrate the utility of the method.     

KEY TECHNOLOGY IN INTELLIGENT CONTROL FOR SHEET METAL DEEP DRAWING

Introduction　　 With development of economics and furtheropening,competitions in market are intensive.The margin between the material cost and price ofproducts becomes small,which compels companiesto pursue higher rate of productivity and quality.The rate of productivity has been improvedthrough high pressing automation,but in order toget satisfactory quality of products under distur-bances,on- line measurement,identification,pre-diction and on- line control must be realized. Intel-ligentcont…     

货车冲压件CAPP系统的研究

针对货车板材冲压件,就开发其CAPP系统进行了研究。以成组技术的基本原理为依据,提出了零件描述和工艺过程生成的新方法,其主要特点是:计算机辅助编码,运用专家知识库进行决策判断,检索与创成相结合。系统采用模块化的设计方法,做到了系统的柔性化。系统采用了汉字DBASE数据库和MS-PASCAL语言,适用于IBM-PC机及其兼容机。     

Galling failure analysis in sheet metal forming process

Galling is a known failure mechanism in sheet metal forming operations,and it can lead to fracture of the products and jamming of the tool. The temperature field and normal contact pressure distributions of the tool and the blank were studied with a finite element analysis model under the action of different blank holder force and frictional coefficient. A series of forming tests of the high strength steel were conducted to validate the finite element model. The characteristics of galling failure,the damage...     

Application of neural network to downhill shift strategy for automatic transmission

A method is proposed to estimate the longitudinal road gradient with a concept “general gradient force (GGF)”, in which uncertain factors such as additional vertical load, road surface change, and strong wind are also taken into account. An adaptive downhill shift control system is then developed to help driver to use the engine brake with lower gears while downhill driving. In the adaptive system, a three-layer neural network is built to evaluate the necessity to make use of engine brake capability in current downhill situation, and the neural network is trained with samples from experienced drivers. Field test results of the adaptive system are introduced to verify the effectiveness of the approach mentioned above.     

Investigation on blanking of thick sheet metal using the ductile fracture initiation and propagation criterion

In metal forming processes such as sheet blanking, severe plastic deformation localizes in a narrow shear band near blanking clearance, and ductile fracture occurs at the final stage. Because the combinations of large nonlinear strain localization, displacement discontinuity and ductile fracture brought obstacles to numerical simulation, a ductile fracture initiation criterion model and an elasto-plastic finite element method (FEM) were presented to simulate localized severe plastic deformation. Initiation and propagation of cracks were treated by deletion-and-replacement approach. The distributions and developing trends of effective strain and damage were predicted, the influence of blanking clearance on fracture was discussed, and an experiment was performed to explore the forming mechanism.     

Feasibility study for the application of air inflated membrane structure in China National Stadium

China National Stadium, also known as “Bird’s Nest”, is the main stadium of the 29th Olympic Games in Beijing in 2008, which has successfully held not only the Opening and the Closing ceremonies but also the track and field events. A new problem of rain preventing is brought out to improve the utilization of the Bird’s Nest after the Olympic Games. The scheme of installing an air inflated membrane at the opening of the steel structure is proposed in this paper to solve the rainproof problem of the Bird’s Nest. The form-finding and mechanical analyses of the air inflated membrane are carried out. Comparison between the mechanical performance and dynamical character before and after installing the air inflated membrane structure is given. To verify the analysis results, based on the practical structure of the Bird’s Nest, a test of a 1:20 model membrane is worked out.     

A bintree energy approach for colour image segmentation using adaptive channel selection

A new hierarchical approach called bintree energy segmentation was presented for color image segmentation. The image features are extracted by adaptive clustering on multi-channel data at each level and used as the criteria to dynamically select the best chromatic channel, where the segmentation is carried out. In this approach, an extended direct energy computation method based on the Chan-Vese model was proposed to segment the selected channel, and the segmentation outputs are then fused with other channels into new images, from which a new channel with better features is selected for the second round segmentation. This procedure is repeated until the preset condition is met. Finally, a binary segmentation tree is formed, in which each leaf represents a class of objects with a distinctive color. To facilitate the data organization, image background is employed in segmentation and channels fusion. The bintree energy segmentation exploits color information involved in all channels data and tries to optimize the global segmentation result by choosing the ＂best＂ channel for segmentation at each level. The experiments show that the method is effective in speed, accuracy and flexibility.     

Investigation on Two Electrically-Assisted Forming Processes of AZ31B Magnesium Alloy Sheets

Two new types of electrically-assisted forming(EAF) processes of AZ31B magnesium alloy sheets,i.e., electrically-assisted blanking(EAB) and electrically-assisted sheet upset-extruding(EASUE), are proposed in this paper. During EAB, pulsed current(PC) decreases blanking load and improves blanked surface quality,and higher frequency has a more effective improvement; when the frequency reaches 600 Hz, the whole punched hole fracture is improved to smooth zone. Moreover, EAB does not influence the microstructure and does not induce obvious annealing, and this process is advantageous to the materials that cannot change microstructure.During EASUE, PC can reduce extrusion load and enhance extrusion height, and higher frequency also has a more effective improvement. Both processes indicate that introducing PC can effectively improve the part quality and have an application prospection.     

Structure-borne sound attenuation at corner interface with dynamic vibration absorber attached

Structure-borne sound attenuation at corner interface of two plates with dynamic vibration absorber attached is investigated by wave approach. Equations governing transmission and reflection coefficients are deduced by introducing some non-dimensional coefficients, which help to reveal the physical sense inside and to simplify the analysis. Numerical investigation on vibration energy transmission of bending wave is carried out as well. The results from measurement and prediction show almost the same trends in the simplified experiment. It is found that energy transmission at corner interface depends greatly on whether the dynamic vibration absorber attached acts at resonance and is relatively lower right after the nature frequency of dynamic vibration absorber. Furthermore, the dynamic vibration absorber attached provides less energy transmission of bending wave than blocking mass at the end of “passing band”.     

FORMING FREEFORM SURFACE SHEET METAL USING INTEGRATED REVERSE ENGINEERING TECHNOLOGY

IntroductionReverse engineering in the manufacturing fieldis a process that people first measure an existentobject model or a part to obtain its data,then re-construct its CAD model. The CAD model repre-sents the geometric features and other propertiesoforiginal object and also can be used for many otherpurposes,such as analysis,modification,manu-facturing and test etc.The main difference be-tween conventional forward engineering and re-verse engineering is that the former is an explicitphys…     

前挤压工件和模具的温度分布有限元分析

在高精密冷成形加工中，工件和模具的温度变化直接影响工件的成形精度，通过对前挤压加工过程机械热力偶合有限元模拟，对材料的流动，由于塑料变形和接触面之间的摩擦所产生的热量，工件和模具中的热传导，工件与模具之间的热交换，在成形期间和其后冷却过程工件和模具中温度的分布等进行了分析，对工件和模具的机械和热力学性能和诸如冲头的速度，摩擦系数等加工条件对温度在工件和模具中的分布的影响进行了研究，有限元模型的结果表明，在成形加工中由于热膨胀和冷却的影响，工件和模具中温度的变化将影响工件的成形精度，工件的性能对热的产生和温度分布有决定性的影响，加工条件的变化会影响温度的高低和分布。