scholarly journals Investigation on Ultra-high Temperature Forging Process Based on DEFORM-3D Simulation

2021 ◽  
Author(s):  
Wu Yong-qiang ◽  
Wang Kai-kun
Keyword(s):  
High Temperature ◽  
Equivalent Stress ◽  
Strain Curve ◽  
Green Manufacturing ◽  
Equivalent Strain ◽  
Temperature Fields ◽  
Forging Process ◽  
Reheating Process ◽  
Deform 3D ◽  
Ultra High Temperature

Abstract Green manufacturing and forming technology is becoming increasingly important in modern industry. In this study, a new forging technology with the ultra-high temperature demoulding is introduced, in which conventional reheating process could be avoided. The DEFORM-3D software simulated the forging process and the temperature fields were obtained. The traditional forging process was simulated when the initial forging temperature was 1220℃. The highest temperature of the ingot in the new forging technology was about 200℃ higher than that of the traditional forging process. We cut the ingot longitudinally along the centerline. Nine points on the axis of the cutting plane and nine points on the radial direction were selected. The equivalent stress and the equivalent strain of these points were compared respectively under the two forging processes by using the particle tracking method. The variation laws of the equivalent stress and the equivalent strain with the reduction were obtained. According to the variation laws, the typical points which were easy to crack under two different forging processes were found. Based on the flow stress-strain curve calculated by the software JMatPro®, the new forging technology could avoid hot cracking.

Die Forging Process Simulation of a Connecting Rod

2011 ◽  
Vol 704-705 ◽  
pp. 302-307
Author(s):  
Lei Xu ◽  
Guang Ze Dai ◽  
Xing Ming Huang ◽  
Jing Han ◽  
Jun Wen Zhao
Keyword(s):  
Reduction Rate ◽  
Temperature Fields ◽  
Stress Fields ◽  
Connecting Rod ◽  
Preheat Temperature ◽  
Forging Process ◽  
Optimum Parameters ◽  
Die Forging ◽  
High Level ◽  
Deform 3D

Numerical simulation of connecting rod die forging processing was performed by finite element method (FEM) software Deform 3D. The changes of the temperature fields, stress fields of the billet and dies, and upper setting force-stroke curve during the die forging were obtained. The simulation results show that (1) the increase of the fillet radius of dies could effectively reduce the stress concentration so that to prevent the die crack arising at high level stress; (2) the optimum parameters of die forging process are 430°C for forging temperature, 200°C for preheat temperature of dies and 80mm/s for reduction rate by comparing both fields of the stress and temperature during different forging process..

Elasto-plastic and creep behaviour of axially loaded, shouldered tubes

1980 ◽  
Vol 15 (1) ◽  
pp. 21-29 ◽  
Author(s):  
R J Dawson ◽  
H Fessler ◽  
T H Hyde ◽  
J J Webster
Keyword(s):  
Finite Element ◽  
Creep Behaviour ◽  
Equivalent Stress ◽  
Strain Curve ◽  
Equivalent Strain ◽  
Uniaxial Tensile ◽  
Plastic Strain Increment ◽  
Axially Loaded ◽  
Initial Strains ◽  
Creep Strains

This paper compares the finite element predictions of elasto-plastic and creep behaviour with experimental data for axially loaded, shouldered tube models. Four shouldered tube models were made of a lead alloy and tested at 61°C, using strain gauges to measure the elasto-plastic and creep strains in the plain tube and fillet regions of the models. Instantaneous stress-strain and creep data were obtained from strain-gauged, uniaxial tensile specimens. The finite element solutions are based on the incremental Prandtl-Reuss equations. The elasto-plastic iterative solutions use a ‘negative gradient’ from the calculated point to the equivalent stress-equivalent strain curve to get the next estimate of the plastic strain increment. A time incremental method is used to obtain the creep solutions. Tests with the mean tube stress below, at and above the yield stress showed very good agreement between prediction and measurement of initial strains in the fillets. Differences between predictions and measurements of creep strains are attributable to cast-to-cast variations.

Study on Precision Forging Schemes of Hypoid Driving Gear

2012 ◽  
Vol 472-475 ◽  
pp. 692-695
Author(s):  
Jian Hua Wang ◽  
Fu Xiao Chen
Keyword(s):  
Equivalent Stress ◽  
Three Dimensional ◽  
Equivalent Strain ◽  
Precision Forging ◽  
Forming Technology ◽  
Blank Shape ◽  
Simulation Results ◽  
Three Dimensional Models ◽  
3D Software ◽  
Deform 3D

By analyzing the characteristics and forming technology of hypoid driving gear, it was suitable for adopting fully enclosed die forging principle to form the gear. Based on different forging methods, three kinds of blank shape and corresponding forming schemes were designed. The three dimensional models of blank and die were created by the UG software. The three forming schemes were simulated by the Deform-3D software. The simulation results of distribution of equivalent stress, distribution of equivalent strain and load-stroke curve were comparatively analyzed. Then the most reasonable scheme was chosen. At last, the rationality of numerical simulation can be further verified by the optimized scheme was proved by experiment.

Determining the Anisotropy Coefficients of an Ultra Fine Grained Al6082 Alloy Subjected to ECAP

2007 ◽  
Vol 537-538 ◽  
pp. 215-222
Author(s):  
György Krállics ◽  
Arpad Fodor
Keyword(s):  
Constitutive Equation ◽  
Yield Stress ◽  
Continuum Mechanics ◽  
Equivalent Stress ◽  
Strain Curve ◽  
Equivalent Strain ◽  
Rigid Plastic ◽  
Fine Grained ◽  
Anisotropy Coefficients

Bulk Al6082 alloy is subjected to ECAP using route Bc. This paper focuses on the determination of the anisotropy coefficients and equivalent stress-equivalent strain curve using continuum mechanics equations. Assuming the material to be rigid-plastic, the parameters of the constitutive equation are determined with the aid of measuring the deformation and the uniaxial yield stress during upsetting tests in three perpendicular directions.

scholarly journals The Simulation of the Preparation of the Ingot With Liquid Core

2021 ◽  
Author(s):  
yongqiang wu ◽  
Zhi-ren Sun ◽  
Kaikun Wang
Keyword(s):  
Finite Element ◽  
High Temperature ◽  
Liquid Phase ◽  
Solid Phase ◽  
Liquid Core ◽  
Phase Region ◽  
Simulation Results ◽  
Solid Liquid ◽  
Deform 3D ◽  
Ultra High Temperature

Abstract During the preparation of the ingot with liquid core in the early stage, the finite element models of the solidification and the ultra-high temperature demoulding were established in DEFORM-3D. The thermophysical properties of ASSAB 718 with the variations of C, Mn and Cr were calculated in JMatPro®. The material database was imported into DEFORM-3D. Through the analysis of the finite element simulation results, we obtained the influence of three main elements C, Mn and Cr contents on the size of the solid-phase region, the liquid-phase region and the solid-liquid two-phase region in the ingot. We optimized the composition of the material to get a wide solid-liquid phase range. The high carbon, the medium manganese and the high chromium contents were beneficial to form the liquid core. Based on the method of the solidification time, the algorithm was programmed by the python language. We analyzed the influence of the three elements C, Mn, and Cr on the concentration distribution based on the temperature field data, which were obtained by DEFORM-2D after the solidification and the ultra-high temperature demoulding. According to the simulation results, we found that the region prone to negative segregation.

scholarly journals Exploring Strong Spinning Formation Mechanisms of GH3030 Superalloy Tapered Rotary Part with Wall Thickness Gradient

2019 ◽  
Vol 37 (4) ◽  
pp. 785-793
Author(s):  
Xuedao Shu ◽  
Zewei Cen ◽  
Yu Wang ◽  
Zixuan Li ◽  
Ying Zhu
Keyword(s):  
Finite Element ◽  
Stress Field ◽  
Wall Thickness ◽  
Equivalent Stress ◽  
Strain Curve ◽  
Element Model ◽  
Equivalent Strain ◽  
Formation Mechanisms ◽  
Distribution Law ◽  
Metal Casing

In order to effectively control the deformation of tapered spinning parts with gradually changing wall thickness, the precise forming of such sheet metal casing parts can be realized. This paper uses experiments to establish the true stress-strain curve equations of GH3030 superalloy at normal temperature. Based on the equations, it establishes the finite element model of the strong spinning forming of a GH3030 superalloy tapered rotary part with wall thickness gradient. The equivalent stress field for the strong spinning forming is used to combine the finite element simulation with experiments. The strong spinning forming is simulated, and the distribution characteristics of the equivalent stress field and the equivalent strain field for the strong spinning forming are analyzed in some detail, and their distribution law is obtained. The strong spinning forming mechanisms for the GH3030 superalloy tapered rotary part with wall thickness gradient is clarified. The experimental and simulation results are verified with the conical flange plane degree.

CAE Analysis on the Precision Forging of Big Semimonocoque of Vehicle Axle

2015 ◽  
Vol 713-715 ◽  
pp. 200-204
Author(s):  
Ju Li Li ◽  
Xiao Xi Wang ◽  
Rui He ◽  
Xin Xin Qian
Keyword(s):  
Strain Distribution ◽  
Equivalent Stress ◽  
Process Research ◽  
Technological Parameters ◽  
Forging Process ◽  
Precision Forging ◽  
Cae Analysis ◽  
Metal Materials ◽  
3D Software ◽  
Deform 3D

A CAE analysis on the precision forging of big semimonocoque of vehicle axle was conducted based on DEFORM-3D software. It discussed effects of forging billet size and shape on the forging property and effect of forging shape on the flow law of metal materials, and analyzed equivalent stress, strain distribution and load-stroke curve during the forging process. Research results are used to optimize mold structure and technological parameters. Precision forging of big semimonocoque was verified valid by practical production.

Finite Element Analysis of Rolling Process for Pilger Mill

2014 ◽  
Vol 881-883 ◽  
pp. 1420-1423 ◽  
Author(s):  
Ning An ◽  
Liu Hai
Keyword(s):  
Rolling Force ◽  
Equivalent Stress ◽  
Rolling Process ◽  
Equivalent Strain ◽  
Roll Pass ◽  
Element Analysis ◽  
Pipe Rolling ◽  
Cold Rolled ◽  
Simulation Results ◽  
Deform 3D

For the simulation of cold rolled 20Cr steel pipe rolling process the DEFORM-3D being used, the simulation results include the equivalent stress, equivalent strain and rolling force distribution in deformation zone. The stress state of the pipe reducer section is analyzed, analysis shows that the simulation result is approximate the theoretical calculation. The simulation result shows the roll pass and openning effect on the rolling pipe. A view put forward is to compare the simulation results with the actual production and find out their differences. A proposal is made to establish a corresponding database based on simulation and production data.

Two Dimensional Quasi-Steady Molecular Statics Nanocutting Simulation for Cutting Copper Material with Point Defect

2011 ◽  
Vol 264-265 ◽  
pp. 1357-1363
Author(s):  
Zone Ching Lin ◽  
Jia Rong Ye
Keyword(s):  
Point Defect ◽  
Copper Atom ◽  
Equivalent Stress ◽  
Strain Curve ◽  
Equivalent Strain ◽  
Two Dimensional ◽  
Molecular Statics ◽  
One Step ◽  
Copper Material ◽  
The Relationship

This article presents a quasi-steady molecular statics nanocutting simulation model for simulating orthogonal two dimension cutting copper materials with different point defects by using diamond cutters. The analyses of cutting action, cutting force, equivalent strain and equivalent stress are taken during nanocutting copper material with point defect. The two dimensional quasisteady molecular statics nanocutting model first assumes the trajectory of each atom of copper workpiece being cut whenever the diamond cutter goes forward one step. It then uses the Hooke- Jeeves search method to solve the force equilibrium equation of the Morse force in X and Y directions when each copper atom moves a small distance, so as to find the new movement position of each copper atom. Then, the displacement of the acquired new position of each atom combined with the concept of shape function of finite element method are employed to calculate the equivalent strain of the copper workpiece during nanocutting . By using the relationship equation of the flow stress-strain curve, the equivalent stress of the copper workpiece during cutting can also be calculated

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