Feasibility Study on Forming Hollow Axle with Multi-Wedge Synchrostep by Cross Wedge Rolling

2012 ◽  
Vol 201-202 ◽  
pp. 673-677 ◽  
Author(s):  
Bao Sou Sun ◽  
Xue Lei Zeng ◽  
Xue Dao Shu ◽  
Wen Fei Peng ◽  
Pei Sun
Keyword(s):  
3D Model ◽  
High Efficiency ◽  
Cross Wedge Rolling ◽  
Hollow Shaft ◽  
Element Simulation ◽  
Near Net Shape ◽  
Net Shape Forming ◽  
3D Software ◽  
Rolling Technology ◽  
Deform 3D

One direction of the cross wedge rolling technology is to realize high-efficiency, precise and near-net-shape forming hollow axle with multi-wedge synchrostep cross wedge rolling. This paper deduced the rotated condition of forming hollow shaft with multi-wedge cross wedge rolling (MCWR) base on forming solid shaft with single-wedge cross wedge rolling, and analyzed technics parameters on the influence of rotated conditions. Through the finite element simulation we got rolling technics parameters on the effect of rolled piece and selecting principle, and then created the 3D model of the equal diameter period of hollow axle with the MCWR. By using DEFORM-3D software, the process of rolling equal diameter period was simulated. The result indicated that it is feasible to roll hollow axle with multi-wedge synchrostep by cross wedge rolling.

Study on Influencing Factors of Tooth Forming Quality for Gear Shaft with Cross Wedge Rolling

2012 ◽  
Vol 201-202 ◽  
pp. 1164-1169 ◽  
Author(s):  
Mei Zhen Jin ◽  
Jun Hao Li ◽  
Fu Qiang Ying
Keyword(s):  
High Efficiency ◽  
Research Model ◽  
Test Program ◽  
Cross Wedge Rolling ◽  
Material Loss ◽  
Forming Quality ◽  
Number Of Teeth ◽  
Plastic Forming ◽  
Rolling Technology ◽  
Deform 3D

The feature of the gear shaft with Cross wedge rolling technology is high efficiency, low material loss and higher strength of the gear shaft forming. A research model of cross wedge rolling plastic forming adopting tri-dimensional thermal elastic-plastic finite element method is put forward. Forming mold divided into two parts as the wedge-shaped molds and tooth mold is designed. Depending on orthogonal test program, applying Deform-3D to numerical simulate for the gear shaft with cross wedge rolling, the influence of temperature, number of teeth, module and feet rate for gear shaft tooth forming quality is studied. The results are analyzed with the temperature of the workpiece, number of teeth, module and feet rate of the die movement during CWR and the best combination of produce conditions is reached.

Finite Element Simulation of Shearing Force in Disc Slitting Process

2014 ◽  
Vol 1027 ◽  
pp. 150-155 ◽  
Author(s):  
Xian Jing Shi ◽  
Qiu Sheng Yan ◽  
Jia Bin Lu ◽  
Jun Zeng
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Surface Morphology ◽  
3D Model ◽  
Shearing Force ◽  
Actual Result ◽  
Element Simulation ◽  
3D Software ◽  
Deform 3D ◽  
Good Agreement

Based on the principle of disc slitting process, a 3D model of the disc slitting process for galvanized sheet was established by using DEFORM-3D software, and the deformation, fracture and material effective stress of galvanized sheet were analyzed. The surface morphology of numerical simulation is in good agreement with the actual result. The curve of shearing force was obtained and well matched with the change rule of slitting process. Compared with the theoretical calculation result, the simulation result is reliable and can provide a reference for the calculation of shearing force.

The Quality Improvement in Manufacturing “Screw”-Parts Using the DEFORM-3D Software

2016 ◽  
Vol 684 ◽  
pp. 468-472 ◽  
Author(s):  
Sergey Zvonov ◽  
Aleksey Shlyapugin
Keyword(s):  
Aluminum Alloy ◽  
Quality Improvement ◽  
High Speed ◽  
Strain State ◽  
High Efficiency ◽  
Metal Flow ◽  
Stress Strain ◽  
Stress Strain State ◽  
3D Software ◽  
Deform 3D

The check of developed inventory for high-speed stamping "Screw"-part forging fabricated from aluminum alloy by using DEFORM is performed. The high efficiency of the program is shown. The characteristic of metal flow and stress-strain state during the processing is opened.

Finite Element Simulation of Punch Shear during Hole Piercing in Auto Chain Components

2017 ◽  
Vol 9 (3) ◽  
Author(s):  
K.S. Sekar ◽  
K. Sudhagar ◽  
S.N. Murugesan
Keyword(s):  
Fem Simulation ◽  
Steel Component ◽  
Element Simulation ◽  
Simulation Based ◽  
The Press ◽  
Metal Stamping ◽  
Punch Load ◽  
Simulation Results ◽  
3D Software ◽  
Deform 3D

The capabilities of presses are sometimes limited due to larger cutting force requirement for some sheet metal operations. Reducing the tonnage requirements for such operations will sometimes make the presses capable of doing such operations. FEM simulation can be a reliable tool in predicting the amount of tonnage required for the metal stamping operation. An attempt is taken in this study to analyse the behaviour of the hole piercing operation in an automobile chain part using DEFORM 3D software. The main focus is on the prediction of tonnage requirement with different shear methods on the piercing. Simulations were conducted with flat, single sheared, double sheared, reverse double sheared, convex sheared and concave sheared punches and analyzed for variations in the press load. The phenomena of piercing are also observed through the simulation based on AISI 1060 steel component used for automobile chain as inner plate. Simulation results showed that the shear angles provided on piercing punches will reduce the punch load significantly.

Theoretical and Experimental Research on a Method for Producing a Triangular Rosette-Shaped Flange

2014 ◽  
Vol 622-623 ◽  
pp. 1166-1172 ◽  
Author(s):  
Andrzej Gontarz ◽  
Zbigniew Pater ◽  
Janusz Tomczak ◽  
Grzegorz Winiarski
Keyword(s):  
Experimental Tests ◽  
Strength Properties ◽  
Production Costs ◽  
New Method ◽  
Propeller Shaft ◽  
Hollow Shaft ◽  
3D Software ◽  
Forging Press ◽  
Deform 3D ◽  
Lower Production

The paper presents a new method for forming a hollow shaft with a triangular rosette-shaped flange on its end. The part being investigated is used as a propeller shaft in helicopters. The product must be monolithic, therefore it cannot be produced by methods which consist in joining a flange with a tube. Up till now, such shafts have been produced by machining from solid barstock, the process which generates material losses exceeding 90%. The application of the proposed flanging method results in a significant reduction in both material and labour consumption, which leads to lower production costs. Due to beneficial texture of the shaft flange, shafts produced by this method exhibit better strength properties than shafts produced by machining. The paper presents the results of a numerical analysis of the flanging process, performed using DEFORM-3D software. Also, experimental tests were conducted using a three-slide forging press. Theoretical and experimental results obtained confirm the effectiveness of the new method for forming this part.

Effects of Friction on Precision Forging Process of Blade with a Damper Platform

2007 ◽  
Vol 561-565 ◽  
pp. 831-834 ◽  
Author(s):  
Yu Li Liu ◽  
He Yang ◽  
Tao Gao
Keyword(s):  
High Efficiency ◽  
Metal Flow ◽  
Vibration Characteristic ◽  
Technological Parameters ◽  
Forging Process ◽  
Precision Forging ◽  
Blade Forging ◽  
Deformation Defects ◽  
3D Software ◽  
Deform 3D

A blade with a damper platform, with excellent anti-vibration characteristic and high efficiency, has become one of the most important types of blades being developed in the aeronautical engines. During the precision forging process of this blade, the friction between dies and workpiece has important effects on metal flow, deformation defects, load and energy etc. So researching the effects of friction conditions on the forging process of blade with a damper platform has been a crucial problem urgent to be resolved. In this paper, the precision forging process of titanium alloy blade with a damper platform under different friction conditions has been simulated and analyzed based on the DEFORM-3D software platform. The obtained results reveal the influence laws of friction on temperature field and load-stroke curves, and provide a significant basis for determining technological parameters of the blade forging process.

Research on the Status and Prospect of the Hollow Shafts Forming Technology in High-Speed Train

2012 ◽  
Vol 201-202 ◽  
pp. 1071-1075
Author(s):  
Shu Hua Zheng ◽  
Wen Fei Peng ◽  
Xue Dao Shu
Keyword(s):  
High Speed ◽  
High Efficiency ◽  
Lightweight Construction ◽  
Cross Wedge Rolling ◽  
Heavy Load ◽  
Hollow Shaft ◽  
Forming Technology ◽  
The Status ◽  
New Type ◽  
Hollow Shafts

High-speed and heavy-load are the targets to pursue over a long period of time in high-speed transportation. The key to solve this problem is making the components lightweight. Particularly, the hollow shaft is a new type of lightweight construction. This article explains systematically the current situation and the defects of forming technique for the hollow shafts. The solid shafts formed by Multi-Wedge Cross Wedge Rolling (MCWR) and the hollow shafts by Cross Wedge Rolling(CWR) are researched, and the key problems of hollow shafts formed in MCWR to solve emphatically are pointed out. At the same time, we obtain that MCWR will be the main technology in forming long shafts. The results in this paper provide a new direction for the hollow shafts to form in a high efficiency, energy saving and material saving method.

Effect of Die Clearance on Peak Punching Force During Cryogenic Micropunching of Polycaprolactone

2020 ◽  
Vol 4 (1) ◽  
Author(s):  
Amrit Sagar ◽  
Christopher Nehme ◽  
Anil Saigal ◽  
Thomas P. James
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Three Dimensional ◽  
Porous Membranes ◽  
Element Simulation ◽  
Key Factor ◽  
Punching Process ◽  
3D Software ◽  
Deform 3D ◽  
Cryogenic Conditions

Abstract Microscale holes were punched at cryogenic conditions in polycaprolactone (PCL) membranes to create synthetic three-dimensional (3D) tissue scaffolds through multilayer stacking of two-dimensional (2D) porous membranes. Punching forces were experimentally measured, and finite element modeling of the punching process was validated by comparing punching force results. Holes of nominal diameter of 200 μm were punched in PCL films of two different thicknesses: 40 μm and 70 μm. Die clearances used for holes in 40 μm thick films were 15.0%, 30.0%, and 45.0%. Die clearances used for holes in 70 μm films were 8.6%, 17.1%, and 25.7%. All holes were punched while the PCL film was in thermal equilibrium with a bath of boiling liquid nitrogen. Punching forces were analyzed to study the effect of die clearance and film thickness. A 3D finite element simulation of the punching process was done using deform 3d software. Cryogenic material properties of PCL used in the simulation were determined experimentally. It was concluded that finite element simulation for the cryogenic micropunching process can be used to predict peak punching forces with reasonable accuracy, which is a key factor to be considered while designing the punching dies. The finite element simulations did not predict an optimal die clearance to minimize peak punching force. However, the measured peak punching forces for 70 μm thick film seem to favor the smallest die clearance to minimize peak punching force.

scholarly journals Study on the Dynamic Recrystallization Behavior of 47Zr-45Ti-5Al-3V Alloy by CA–FE Simulation

Materials ◽  
2021 ◽  
Vol 14 (10) ◽  
pp. 2562
Author(s):  
Wenwei Zhang ◽  
Qiuyue Yang ◽  
Yuanbiao Tan ◽  
Ya Yang ◽  
Song Xiang ◽  
...  
Keyword(s):  
Dynamic Recrystallization ◽  
Volume Fraction ◽  
Simulation Method ◽  
Hot Working ◽  
Kinetics Models ◽  
Element Simulation ◽  
Dynamic Recrystallization Behavior ◽  
Working Parameters ◽  
3D Software ◽  
Deform 3D

The dynamic recrystallization (DRX) behavior of 47Zr-45Ti-5Al-3V alloy was studied by using the experiment and numerical simulation method based on DEFORM-3D software and cellular automata (CA) over a range of deformation temperatures (850 to 1050 °C) and strain rates (10−3 to 100 s−1). The results reveal that the DRX behavior of 47Zr-45Ti-5Al-3V alloy strongly depends on hot-working parameters. With rising deformation temperature (T) and decreasing strain rate (ε˙), the grain size (dDRX) and volume fraction (XDRX) of DRX dramatically boost. The kinetics models of the dDRX and XDRX of DRX grains were established. According to the developed kinetics models for DRX of 47Zr-45Ti-5Al-3V alloy, the distributions of the dDRX and XDRX for DRX grains were predicted by DEFORM-3D. DRX microstructure evolution is simulated by CA. The correlation of the kinetics model is verified by comparing the dDRX and XDRX between the experimental and finite element simulation (FEM) results. The nucleation and growth of dynamic recrystallization grains in 47Zr-45Ti-5Al-3V alloy during hot-working can be simulated accurately by CA simulation, comparing with FEM.

Analysis of Stress and Strain on Shaft Parts for Closed Type of Cross Wedge Rolling during Stretching Stage

2015 ◽  
Vol 1095 ◽  
pp. 684-688
Author(s):  
Kai Yu Ji ◽  
Xue Dao Shu ◽  
Chao Cheng
Keyword(s):  
Engineering Application ◽  
Stress And Strain ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Finite Element Software ◽  
Closed Type ◽  
Theoretical Significance ◽  
Rolling Technology ◽  
Deform 3D

To improve the quality of shafts parts end in cross wedge rolling, this paper applied closed type of cross wedge rolling technology to form shaft parts. By using finite element software DEFORM-3D, simulation of forming process for closed type of cross wedge rolling was carried out. The distribution of the stress field and strain field during stretching stage is characterized as the metallic flowing of the rolling forming process. These results have great theoretical significance and engineering application value in the study of the generated mechanism of the end concavity for the closed type of cross wedge rolling and the improvement of the quality of rolled piece end.

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