The Technological Optimization of Closed Multiple-Ram Forging for Draw Rod

2010 ◽  
Vol 29-32 ◽  
pp. 2339-2344
Author(s):  
Chun Dong Zhu ◽  
Tai Liang Dai ◽  
Hui Wang
Keyword(s):  
Numerical Simulation ◽  
Steering System ◽  
Original Material ◽  
Forming Process ◽  
High Quality ◽  
Mechanical Parts ◽  
Optimal Technology ◽  
Simulation Results ◽  
Material Utilization ◽  
Open Die Forging

Draw rod is one of the main mechanical parts of vehicle steering system，which is required extremely high quality. At present the way to produce the draw rod is machining after common open-die forging. This technology will produce big flashings，damage the metal’s fibrous structure and reduce the material utilization. In this essay, we will use the technology of closed multiple-ram forging to produce it. We will utilize numerical simulation on several blanks through numerical simulation combined with experiments. In this way, the defects that some parts of the blank are folded and cannot fill well during forming process can be effectively avoided. Besides, there will be free of flashing and the draw rod forgings do not need to be cut. The weight of the original blank will be about 3.5 kg after being optimized, down by 36.4 percent compared with that of original material about 5.5 kg. And we will make different settings for the loading way of the plunger chips during the forming process, then compare with the simulation results and ultimately find out the best loading way. At last, we will verify the feasibility of such an optimal technology through experiments on the material-lead.

The Numerical Simulation of Conductive Body Forming Process and Mould Design

2011 ◽  
Vol 704-705 ◽  
pp. 177-182
Author(s):  
Jian Xin Gao ◽  
Pei Feng Zhao ◽  
Ke Xing Song ◽  
Qing Wang
Keyword(s):  
Numerical Simulation ◽  
Machining Process ◽  
Forming Process ◽  
Die Forging ◽  
Conductive Body ◽  
Closed Die Forging ◽  
Draft Angle ◽  
Simulation Results ◽  
Open Die Forging ◽  
Ring Blank

T2-copper conductive body is a important part used in high voltage switch, it has poor machining process due to the complex shape. Through Deform numerical simulation, conductive body was formed by open-die forging and closed die forging. In the open-die forging simulation，heat transfer coefficient between blank (880°C) and open-die (200°C) is 11, the surrounding environment temperature is 20°C, friction factor is 0.3. The main open-die forging process parameters is: outer draft angle α=6.5°; inner draft angle β＝10°; bridge width b＝5、8、11mm. punching skin and cylindrical blank. Simulation results show that forging can meet the requirement while properly adjusting mould parameters. The main size of closed-die forging working parts is designed according to the conductive body graph, no draft angle and ring blank of external diameter Φ111mm and inside diameter Φ93mm with the same volume of conductive body. The simulation results shows that forging can be formed using open-die forging, and it is difficult to form product by the process of the closed-die forging for ring blank because of the restriction of solid state metal liquidity, many regions of the filling is not sufficient. Open-die forging and casting blank-closed die forging are both used in actual production. The casting blank-closed die forging is a more reasonable forming process compared with the open-die forging as metal volume of distribution is solved, higher utilization rate of material, more simple process in following work and the like. To make it more suitable for practical production, appropriate adjustments of some parameters was made in the mold design process based on the numerical simulation. Keywords: open-die forging; casting blank–closed die forging; numerical simulation

scholarly journals The Effect of Swinging Ball Heads with Different Arrangements in Multi-Point Stretch-Forming Process

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 337 ◽  
Author(s):  
Jian Xing ◽  
Yan-yan Cheng ◽  
Zhuo Yi
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Sheet Metal ◽  
Strain Distribution ◽  
Finite Element Models ◽  
Stretch Forming ◽  
Forming Process ◽  
Forming Quality ◽  
Staggered Arrangement ◽  
Simulation Results

To improve the effect of multi-point stretch forming of sheet metal, it is proposed in this paper to replace a fixed ball head with a swinging ball head. According to the multi-point dies with different arrangements, this research establishes finite element models of the following stretch forming, i.e., fixed ball heads with conventional arrangement, swinging ball heads with conventional arrangement, swinging ball heads with declining staggered arrangement, and swinging ball heads with parallel staggered arrangement, and then numerical simulation is performed. The simulation results show that by replacing a fixed ball head with a swinging ball head, the surface indentation of the part formed was effectively suppressed, the stress and tension strain distribution of the part formed was improved, and the forming quality was improved; the thickness of the elastic pad was reduced, the springback was reduced and the forming accuracy was improved; and when the ball head was applied to a multi-point die with staggered arrangement, a better forming result was achieved, where the best forming result was achieved in combining the swinging ball heads with the multi-point die with a parallel staggered arrangement. Forming experiments were carried out, and the experimental results were consistent with the trend of numerical simulation results, which verified the correctness of the numerical simulation.

Study on the Forming Process of the Crossmember in Car Intermediate Floor

2013 ◽  
Vol 442 ◽  
pp. 593-598
Author(s):  
Xue Xia Wang ◽  
Peng Chong Guan ◽  
Hai Peng Li ◽  
Li Hui Wang ◽  
Na Zhang ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Process Parameters ◽  
Thickness Distribution ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Simulation Technology ◽  
Forming Process ◽  
Distribution Diagram ◽  
Simulation Results

Flanging and bending forming processes of the crossmember in car intermediate floor are investigated respectively by using numerical simulation technology. The numerical model of the crossmember was established and its press forming effect was simulated to determine the feasible process parameters affecting its manufacturability. Forming limit diagram and thickness distribution diagram are used to evaluate simulation results of different process schemes. And then optimum values of process parameters for flanging and bending are found, which can reduce the tendencies of wrinkling, springback and crackling during the stamping of the product.

Forming Mechanism of Folding Defect within Closed Die Forming Car Steering Knuckle

2011 ◽  
Vol 704-705 ◽  
pp. 240-244 ◽  
Author(s):  
De Ying Zhao ◽  
Lian Dong Zhang ◽  
Li Na Sun
Keyword(s):  
Extrusion Process ◽  
Steering System ◽  
Forming Process ◽  
Forming Mechanism ◽  
Lateral Extrusion ◽  
Folding Defect ◽  
Material Utilization ◽  
Punch Shape ◽  
Die Forming ◽  
Shape And Size

Steering knuckle is the key part of vehicle steering system. The forming technology combined closed die pre-forging with open finish-forging has some advantages such as higher material utilization ratio and lower forming forces and so on. While simulating the closed die extrusion forming process of car steering knuckle, folding defect emerges on the contact area of Branch I and lower punch in the lateral extrusion process. The forming mechanism of the folding defect is studied by numerical simulations and experiments, which mainly consider the influence of lower punch shape and size, extrusion speed and friction conditions to folding length. The results show that the main factors that affect folding defects are the lower punch shape and size. Keywords: steering knuckle, folding defect, closed die forming, numerical simulation, experiment study

Forming Stability Analysis of Surface Flexible Rolling

2013 ◽  
Vol 798-799 ◽  
pp. 267-271
Author(s):  
Ren Jun Li ◽  
Ming Zhe Li ◽  
Zhong Yi Cai
Keyword(s):  
Numerical Simulation ◽  
Stability Analysis ◽  
Sheet Metal ◽  
Three Dimensional ◽  
Continuous Manufacturing ◽  
Forming Process ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Flexible Rolling ◽  
Simulation Results

Surface flexible rolling method, using two integral working rolls as the forming tool, can achieve fast, flexible and continuous manufacturing of three-dimensional sheet metal parts. This paper introduces the basic principle of surface flexible rolling and discusses the numerical simulation results when the working rolls are bended as circular arcs. The stability indicates the forming effect to some extent and the flow type of the metal can be deduced from stability analysis. To integrate and analyze the simulation results by means of reverse engineering. The analysis results show that the forming process is stable and the effect of surface flexible rolling is fine. It also indicates that inhomogeneous deformation and accumulation occurs during the process. The numerical simulation and experimental results demonstrate that the surface flexible rolling is a feasible and effective way to form three-dimensional sheet metal parts.

scholarly journals Differentiation of Optical Signals with Dielectric Ridges on Top of a Slab Waveguide

Vestnik RFFI ◽  
2019 ◽  
pp. 35-45
Author(s):  
Victor A. Soifer ◽  
Nikita V. Golovastikov ◽  
Leonid L. Doskolovich ◽  
Evgeni A. Bezus ◽  
Dmitry A. Bykov
Keyword(s):  
Numerical Simulation ◽  
Oblique Incidence ◽  
Spatial Differentiation ◽  
Slab Waveguide ◽  
High Quality ◽  
Optical Signals ◽  
Quality Differentiation ◽  
Analog Computing ◽  
Planar Structures ◽  
Simulation Results

We propose two simple planar structures that enable spatial differentiation of the profile of optical beams propagating in a slab waveguide. The differentiator operating in transmission consists of a single subwavelength dielectric ridge on the surface of a slab waveguide. The differentiator operating in reflection consists of two grooves on the surface of a slab waveguide. In both cases the differentiation is performed at oblique incidence of the beam and is associated with the resonant excitation of the considered structures eigenmodes localized at the ridge or at the ridge between two grooves. It is shown that the required balance between the differentiation quality and the amplitude of the differentiated beam can be achieved by manipulating the quality factor of the resonance. The presented numerical simulation results demonstrate high-quality differentiation. The proposed differentiator may find application in ultrafast analog computing and signal processing systems.

Effect of Dies Temperature on Mechanical Properties of Hot Stamping Square-Cup Part for Ultra High Strength Steel

2010 ◽  
Vol 129-131 ◽  
pp. 390-394
Author(s):  
Cheng Xi Lei ◽  
Zhong Wen Xing ◽  
Hong Ya Fu
Keyword(s):  
Mechanical Properties ◽  
Numerical Simulation ◽  
Hot Stamping ◽  
High Strength ◽  
Hot Forming ◽  
Forming Process ◽  
Stamping Process ◽  
Ultra High Strength Steel ◽  
Mechanical Properties Testing ◽  
Simulation Results

The numerical simulation of hot-stamping process was carried out for UHSS square-cup parts, and the influence of dies temperature on the hot-stamping process was anlysised. Besides, through the microstructure analysis and mechanical properties testing of the formed parts, effects of dies temperature on microstructures and mechanical properties of hot-stamping square-cup parts were obtained. The experiment and simulation results showed that the mechanical properties of the UHSS are strongly dependent on the temperature, so the dies temperature is one of the most important parameters that have to be taken into account in designing the hot-forming dies and the hot-forming process.

Numerical Simulation on Penetration into Double Plates of Annular Jet

2013 ◽  
Vol 457-458 ◽  
pp. 1523-1526
Author(s):  
Lei Fu ◽  
Wei Li Wang ◽  
Xue Feng Huang ◽  
Ying Zi Jiang ◽  
Zhuang Qing Fan
Keyword(s):  
Numerical Simulation ◽  
Shaped Charge ◽  
Damage Effect ◽  
Kinematic Characteristic ◽  
Jet Formation ◽  
Forming Process ◽  
Annular Jet ◽  
Simulation Results ◽  
Effective Penetration

A new shaped charge annular cutter structure is put forward, and the process of annular jet formation and penetration into double plates is simulated by using ANSYS/LS-DYNA software. The kinematic characteristic of annular jet in the air is analysed. The damage effect on the plates is got. The simulation results show that an intilted phenomenon exists on the forming process of annual jet, and the annular jet is stretched into several annular penetrators after penetrating the upper plate. The annular jet formed by annular cutter shaped charge in the paper can realize effective penetration into double plates, and the results can provide reference for the design of tandem warhead front shaped charge.

How to Combine the Parameters of the Yield Criteria and the Hardening Law

2013 ◽  
Vol 554-557 ◽  
pp. 1195-1202 ◽  
Author(s):  
Pedro Prates ◽  
M.C. Oliveira ◽  
Nataliya A. Sakharova ◽  
José Valdemar Fernandes
Keyword(s):  
Numerical Simulation ◽  
Metal Forming ◽  
Forming Process ◽  
Accurate Identification ◽  
Material Parameters ◽  
Hardening Law ◽  
Out Of Plane ◽  
Simulation Results ◽  
The Hill ◽  
Constitutive Parameters

The numerical simulation of sheet metal forming processes needs the accurate identification of the material parameters, for a given constitutive model. This identification can follow different methodologies and different sets of experimental data can be used, which lead to distinct sets of material parameters. In order to accurately compare the results of several methodologies, it is necessary to guarantee uniformity of their presentation. In this work, the correspondence between sets of parameters of the Hill’48 criterion is explored. The meaning of the “isotropic values” of the parameters associated with the out-of-plane stresses components is discussed and a required condition is proposed, in order to properly compare numerical simulation results obtained by using different input sets of constitutive parameters, identified by different procedures. Finite element simulations of complex shaped forming process, involving strain-path changes, are carried out in order to support the analysis.

Upsetting Process Analysis and Numerical Simulation of Metal Pipe’s End

2013 ◽  
Vol 364 ◽  
pp. 488-492 ◽  
Author(s):  
Yong Lei Su ◽  
Wu Zi Yang ◽  
Chang Ping Wang
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Deformation Zone ◽  
Process Analysis ◽  
New Technology ◽  
Good Match ◽  
Forming Process ◽  
Conical Die ◽  
Metal Deformation ◽  
Simulation Results

Upsetting is a common method in the production of connectors, a new technology to avoid instability of long pipe under compression was taken in this paper, which would get the upsetting shape of long pipe by changing the length of deformation zone. Forming process was simulated by finite element, and some mechanisms of metal deformation and load were obtained. The simulation results showed that: instability was not occurred and one could have specified shape by using conical die upsetting only once. Then the upsetting experiment was conducted, the trail had a good match with simulation results, which expanded upsetting rules, and provided a reference for design of die.

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