Forging penetration efficiency of steel H13 stepped shaft radial forging with GFM forging machine

The numerical thermal mechanical simulation of radial forging process of steel H13 stepped shaft with GFM (Gesellschaft fur Fertigungstechnik und Maschinenbau) forging machine was carried out by three-dimensional finite element code DEFORM 3D. According to the effective plastic strain, the mean stress and the mean plastic strain distribution of the radial forging, the forging penetration efficiency (FPE) was studied throughout each operation. The results show that the effective plastic strain in the center of the forging is always greater than zero for the desirable larger axial drawing velocity. The mean stress in the center of the workpiece is proposed to describe hydrostatic pressure in this paper. There is compressive strain layer beneath the surface of the workpiece to be found, while there is tensile strain core in the center of the workpiece. These results could be a valuable reference for designing the similar forging operations.     

The Numerical Simulation on Hollow Part''''s Precise Sizing Process With Cross-wedge Rolling

ThepaperwassponsoredbyPanDengBprojectIntroductionThecrosswedgerollingprocesshasmnyadVatages.ItisaldndofneweffectiveandeconomictechnologythatProducesstePPedshaft.ThetOchnologyhowtoimPovetheaccuracyofworkPiecehasbeingdeVeoped.ThediametertoleraneofsolidpartscanbelimitedbetWeen0.2mmto0.5mm.Thelengthtolerancerangedbforeen0.2nuntolmm.TheaccuracyofpatscouldsatsfythePfOcisionlevelofthetoleranceandmachiningallowancesofsteeldieforeingChinesenationalstandard.[l]Butthediametertoleranceofhollowpeds…     

Numerical analysis of unconventional forging process of hollowed shaft from Ti-6Al-4V alloy

This paper presents theoretical analysis of unconventional forging process of hollowed shaft from Ti-6Al-4V alloy in a three-slide forging press. This method in comparison with other metal forming methods allows for obtaining of hollowed products. The designed process is verified theoretically by means of numerical simulations based on finite element method with assumption of 3D state of strain. The following factors are considered in the analysis: material flow kinematics, strain distribution, temperature distribution and force of process. On the basis of results, it is stated that the application of designed technology allows for obtaining of a product of assumed quality. A comparison is made between material consumption in analyzed process and material consumption in typical metal forming methods, also in used at present technology of shaft manufacturing by machining only. It is stated that the application of forging in the three-slide forging press allows for a considerable decrease of manufacturing costs due to material savings and decrease of labor consumption of operations at finishing.     

Simulation and analysis of microstructure evolution of IN718 in rotary forgings by FEM

A numerical analysis was performed to study the in?uence of process parameters on the microstruc-ture evolution of IN718 alloy in rotary forging using the finite element method(FEM).For this purpose, a constitutive equation considering the effects of strain hardening and dynamic softening of IN718 alloy was built.The constitutive equation and microstructure models were implemented into the finite element code to investigate the microstructure evolution during rotary forging subject to large deformations.The simulations were carried out in the ratio of initial height to diameter range 0.2-0.8, the angle of the rocker 3°-7° and the relative feed per revolution range 0.01-0.1 r-1.The research results revealed the deformation mechanism and the correlation of process parameters with the grain size evolution of IN718 alloy during rotary forging.These provide evidence for the selection of rotary forging parameters.     

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.     

Microstructure Evolution of Different Forging Processes for 12％Cr Steel During Hot Deformation

Five forging experiments were designed and conducted to investigate the effect of process parameters on microstructure evolution during hot deformation for X12CrMoWVNbN10-1-1 steel.The experimental results indicated that average grain size became finer with the increasing number of upsetting and stretching.Especially,the size of stretching three times with upsetting twice had the most remarkable effect on refinement,and the size was only 27.36%of the original one.Moreover,the stress model was integrated into the software and finite element models were established.Simulation results demonstrated that the strain at center point of workpiece was far larger than critical strain value in each process,so that dynamic recrystallization(DRX) occurred in each workpiece,which implied DRX could occur for several times with the increasing number of upsetting and stretching,and uniform finer microstructure would be obtained.However,the results also showed that higher temperature was an unfavorable factor for grain refinement,so the times of heating should be limited for workpiece,and as many forging processes as possible should be finished in once heating.     

基于有限元分析的透水沥青路面结构优化方案

为深入分析降雨条件下透水沥青路面排水层内部渗流状况,更充分地发挥透水材料的渗透性能优势,对透水沥青路面的结构进行了优化。采用有限元软件SEEP/W,基于非饱和渗流理论分析了排水层在降雨过程中的内部渗流状况,针对影响排水层排水效率的结构性因素,提出了透水沥青路面的结构优化方案,并对该方案进行瞬态模拟。模拟结果表明,与常规方案相比,所提出的优化方案均在不增加排水层材料用量的情况下,大幅度提高了路面排水能力。其中,2%横坡路段,不等厚上面层模型和增设排水沟模型相较常规模型,在对降雨强度的适应能力方面分别提高了38.2%和158.8%;8%横坡路段,不等厚上面层模型和不等厚-增沟模型相较常规模型,在对降雨强度的适应能力方面分别提高了130.8%和234.6%。研究表明,对透水沥青路面结构进行的优化有效提高了其排水性能,增强了透水路面排水层对降雨的应对能力。     

应用电阻应变计的无缝线路纵向力测试原理及方案

针对无缝线路纵向力测试问题,在双向应变法原理的基础上,应用电阻应变计提出了一种新的无缝线路钢轨纵向力测试方案.综合考虑应变计热输出及同一钢轨断面温度非均匀分布的条件下,较为系统的阐述了基于电阻应变计的无缝线路纵向力测试原理,并对较为常用的既有测试方案的测试误差进行了对比分析.结果表明:钢轨断面温度的非均匀分布是测量误差的一个主要来源;采用电阻应变计测量无缝线路钢轨纵向及竖向应变时,必须考虑应变计的热输出以及钢轨纵向及竖向约束不同对相应的应变计热输出的影响;采用电阻应变计直接进行钢轨纵向力测量,无法将钢轨中的基本温度力及伸缩附加力进行分离;本文提出的测试方案不需附加补偿片,能够抵消荷载引起的弯曲应变,当两侧轨腰温差为2 ℃时,测量误差较之既有测试方案分别能够降低84.0%及60.3%.      

Tool Wear Prediction in Micro-end-milling with Hard Material

The applications of micro-machining have increased drastically in the last ten years. However, tools with less than 1mm diameter using for micro-mills have very short and unpredictable life when they are used to cut hard metals. In this study, preliminary design of experiment (DOE) test program was conducted to investigate and identify the factors affecting tool wear at the micro-scale with hard material. Analysis of variance (ANOVA) and Taguchi method were efficient to determine appropriate cutting condition and the effect of parameters. A simple model was also developed to predict the width of slots on the workpiece along the cutting length. The obtained results can provide the basic guidelines for parameter setting of micro-end-milling with hard material.     

铝合金货车侧墙多道焊变形预测

基于热弹塑性有限元法,对铝合金货车侧墙多道焊焊接变形进行仿真预测,仿真中充分考虑了材料热物理属性的影响．基于实体一壳单元混合模型,建立了侧墙有限元网格模型,应用3D高斯双椭球热源模型实现了焊接过程温度场分析．从工程实际出发设计了四种焊接顺序,通过对四种焊序下仿真结果的对比分析,讨论了不同焊接顺序对铝合金货车侧墙焊接成形的影响,为研究大型铝合金薄板焊接过程中的应力应变和减少焊接应力与变形提供了参考依据．     

基于光纤光栅传感技术的江阴大桥结构应变监测研究

江阴大桥自1999年通车以来,就一直经历着大交通和重载交通的双重考验.主桥钢箱梁受交通荷载的影响最为直接,极易因荷载的不断作用而产生疲劳损伤.对荷载影响反应最直接的就是主桥钢箱梁结构的内部应变,通过对结构应变的监测,可以较好地掌握桥梁受动态荷载作用下的结构响应.本文采用光纤光栅传感技术对钢箱梁结构的重点部位进行应变监测...     

Wind pressure distribution and wind-induced dynamic response for spatial groined latticed vaults

The wind pressure distribution and wind-induced vibration responses of long-span spatial groined latticed vaults (SGLVs) were numerically simulated, which always are ones of the most important problems in the structural wind resistance design. Incompressible visco-fluid model was introduced, and the standard k-εtwo equation model and semi-implicit method for pressure linked equation (SIMPLE) were used to describe the flow turbulence. Furthermore, the structural dynamic equation was set up, which is solved by Newmark-β method. And several sort of wind-induced vibration coefficients such as the wind-induced vibration coefficient corresponding to the nodal displacement responses and wind loads were suggested. In the numerical simulation where the SGLV consisting of the cylindrical sectors with different curved surface was chosen as the example,the influence on the relative wind pressure distribution and structural wind-induced vibration responses of the closed or open SGLV caused by such parameters as the number of cylindrical sectors, structural curvature and the ratio of rise to span was investigated. Finally, some useful conclusions on the local wind pressure distribution on the structural surface and the wind-induced vibration coefficients of SGLV were developed.     

Current Density Distribution in Gas Tungsten Arc Welding Process

IntroductionWeldingisacriticaltechnologyinbuildingnuclearreactors,shins,piPelinesandinatomobilemanufaCtuing.BatuPtil1noWtheearemanyproblemsinPractice,understandingthedeVlopmentoftheweldpoolduringweldingisofconsiderablePracticalsignificance.BecauseofthecomPlexityoftheprocessandtl1ePresenceofthebrightarc,directexPerimentalinvestigationsareextremelyexPensiveandoftenimPossibleorimPracticable,thensomemathematicalmethodsareadoptedtosett1PthetfansiellttemPerattirefieldandthefluidflowfieldofthew…     

时变单车路径问题建模及算法设计

讨论了一类时变单车配送路径优化问题。综合考虑车辆行驶速度随时间、路段不同而变化的特点,及车辆为多条路线上的客户提供服务时对车辆路径优化的影响,建立了以配送完成时间最早为优化目标的时变单车配送路径优化模型。在行驶时间满足FIFO规则下,设计了基于Inver-over操作的PSO启发式算法及满足贪婪配送策略下的动态规划精确求解算法,并讨论了增加贪婪补货策略的单车配送路径问题解与原问题解的关系。最后分别用两种算法对算例进行求解,并通过对求解优化结果及计算时间的对比分析验证了IOPSO算法的有效性。     

基于源路由的多路径路由协议

为了进一步有效地利用网络资源，采用多路径机制改善最佳链路状态路由协议OLSR的网络性能．提出了基于源路由的多路径SR-MPOLSR协议．首先利用MPR多点中继机制高效获取网络的拓扑图，并在网络节点中用多重Dijkstra算法计算出多路径．然后采用加权分配的循环调度实现负载分配，最后引人源路由机制完成报文的选径转发．这种SR-MPOLSR协议较之OLSR协议可进一步利用网络资源，改善链路的吞吐量和平均延迟．增加网络健壮性和可靠性．仿真结果显示，与OLSR算法相比，SR-MPOLSR算法的数据传输率提高20％-40％。端对端平均延迟降低10％-30％．     

Coupled Thermo-Mechanical Modeling of Long Cone-Shaped Forging Based on Rigid Visco-Plastic FEM

Based on synthetically considering the coupled thermo-mechanical relations between temperature and deforming,a numerical simulation of the forging process for the special long cone-shaped workpiece of Al-5.44M-2.15L-0.12Zr alloy at high temperature was conducted by using the rigid visco-plastic finite element method.The relations between the total load and the displacement druing the forging ,and the distributions of stress,strain,temperature and strain rate,which can provide useful information for the process design,are obtained.     

The Size Effects on Process Design of Micro Deep Drawing

This paper suggested to reformulate cylindrical deep drawing parameters with dimensionless form. A diagram, in which a feasible zone is drawn to bound both the maximal allowable tension and compression stress during the deep drawing process, was established. Since it is presented in a dimensionless form, it may be applied for both conventional and micro deep drawing. Cylindrical cup deep drawing was taken as an example to show the dimensionless process design method. In addition, the size effects should be taken into account. Two kinds of size effects on micro deep drawing were investigated, which can be explained by surface layer model and strain gradient model. Numerical simulations were carried out to compare the strain distribution with or without consideration of size effect.     

足尺沥青混凝土路面加速加载动力响应

采用足尺沥青混凝土路面加速加载试验设备,检测了移动车辆荷载下路面结构的动力响应,分析了面层底部的动应变和土基顶竖向压应力,研究了车辆轴重、行驶速度和轮胎胎压对路面结构动力响应的影响,分别建立了动力响应与轴重、车速的回归模型,在不同轴重、车速和胎压下对4种路面结构进行了试验。分析结果表明:在行车荷载作用下,面层底部应变响应呈拉压应变交变状态;在中等试验温度条件下,面层底部应变响应随轴重的增加而线性增加,土基顶竖向压应力呈单向应力状态,且随轴重增加而增大;车速显著影响面层底部应变响应,但对竖向压应力影响不大,仅影响应力的脉冲持续时间;随车速增加,应力脉冲时间缩短,面层底部应变响应减小;重载车辆在低速行车时对路面的破坏作用更严重,但胎压对面层底部应变和土基顶竖向压应力影响较小。     

一种难加工材料的斜角切削过程的数值模拟

参数化建模在仿真切削过程中是行之有效的方法。通过接口设计,系统实现了在Marc中对斜角切削方式的参数化建模。基于金属切削理论和有限元分析原理。借助于有限元方法及材料弹塑性变形理论。针对斜角切削方式,通过建立几何模型、材料模型、刀屑摩擦模型、热控模型和切屑分离准则,采用有限元分析软件Marc,对一种难加工材料的切削过程进行数值模拟,得到在不同切削条件下的切削区应力场、温度场。通过对数值模拟后切削力的结果与实验得到的数据进行比较,验证了所建模型的合理性。     

Analysis of the cross-wedge rolling process of toothed shafts made from 2618 aluminium alloy

The paper presents the results of a thermo-mechanical analysis of the rolling two stepped shafts. One of the shafts has a toothed step with skew teeth, while the other has a worm winding in the shape of a trapezoidal screw. The shape of the rolling tools resembles that of the tools used in the Roto-Flo rolling method; yet unlike in Roto-Flo, the shafts are hot-rolled and no centres are used to stabilize the position of the workpiece during the forming process. For the calculations made with use of the DEFORM-3D process simulation system it has been assumed that the rolled shafts are made from 2618 aluminium alloy. As a result of the calculations made, it has been found that the toothed stepped shafts can be formed in one pass by means of the cross rolling process. Additionally, the temperature and strain distribution in the rolled product have been determined as well as some data concerning the forces which are necessary for the rolling process have been obtained.