Search results

1 – 10 of 40
To view the access options for this content please click here
Article
Publication date: 13 November 2009

A.E. Tekkaya and P.A.F. Martins

The purpose of this paper is to provide industrial, education and academic users of computer programs a basic overview of finite elements in metal forming that will enable…

Abstract

Purpose

The purpose of this paper is to provide industrial, education and academic users of computer programs a basic overview of finite elements in metal forming that will enable them to recognize the pitfalls of the existing formulations, identify the possible sources of errors and understand the routes for validating their numerical results.

Design/methodology/approach

The methodology draws from the fundamentals of the finite elements, plasticity and material science to aspects of computer implementation, modelling, accuracy, reliability and validation. The approach is illustrated and enriched with selected examples obtained from research and industrial metal forming applications.

Findings

The presentation is a step towards diminishing the gap being formed between developers of the finite element computer programs and the users having the know‐how on the metal forming technology. It is shown that there are easy and efficient ways of refreshing and upgrading the knowledge and skills of the users without resorting to complicated theoretical and numerical topics that go beyond their knowledge and most often are lectured out of metal forming context.

Originality/value

The overall content of the paper is enhancement of previous work in the field of sheet and bulk metal forming, and from experience in lecturing these topics to students in graduate and post‐graduate courses and to specialists of metal forming from industry.

Details

Engineering Computations, vol. 26 no. 8
Type: Research Article
ISSN: 0264-4401

Keywords

To view the access options for this content please click here
Article
Publication date: 1 August 1998

Jaroslav Mackerle

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming, powder…

Abstract

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming, powder metallurgy and composite material processing are briefly discussed. The range of applications of finite elements on these subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE researchers/users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for 1994‐1996, where 1,370 references are listed. This bibliography is an updating of the paper written by Brannberg and Mackerle which has been published in Engineering Computations, Vol. 11 No. 5, 1994, pp. 413‐55.

Details

Engineering Computations, vol. 15 no. 5
Type: Research Article
ISSN: 0264-4401

Keywords

To view the access options for this content please click here
Article
Publication date: 1 May 1994

N. Brännberg and J. Mackerle

This paper gives a review of the finite element techniques (FE)applied in the area of material processing. The latest trends in metalforming, non‐metal forming and powder…

Abstract

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming and powder metallurgy are briefly discussed. The range of applications of finite elements on the subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for the last five years, and more than 1100 references are listed.

Details

Engineering Computations, vol. 11 no. 5
Type: Research Article
ISSN: 0264-4401

Keywords

To view the access options for this content please click here
Article
Publication date: 1 May 1999

Y.K. Lee and D.Y. Yang

An easy and robust grid‐based approach is proposed to construct the fully hexahedral mesh in three‐dimensional case and its application for the mesh regeneration or…

Abstract

An easy and robust grid‐based approach is proposed to construct the fully hexahedral mesh in three‐dimensional case and its application for the mesh regeneration or remeshing during the finite element simulation of a metal forming process is presented to show the validity and effectiveness of the scheme. The proposed scheme enables the construction of the provisional mesh by superimposing the regular cubical grid over the object to be meshed and removing the exterior grid points and cells. Because the constructed provisional mesh has the discrete rugged boundary that is quite different from the boundary geometry of the object to be meshed, the nodes on the boundary of the provisional mesh are projected onto the object boundary. The main disadvantage of the mesh constructed by grid‐based approaches is its severely distorted elements on the boundary owing to the projection of the rugged boundary onto the object boundary. In order to improve the quality of boundary elements, some layers of elements on the boundary surface are constructed and the nodes are repositioned by mesh smoothing. Consequently, the quality of boundary elements is effectively improved.

Details

Engineering Computations, vol. 16 no. 3
Type: Research Article
ISSN: 0264-4401

Keywords

To view the access options for this content please click here
Article
Publication date: 1 March 2005

J.T. Hong, Y.K. Lee, S.R. Lee and D.Y. Yang

In the finite element analysis of a hot forging process with hexahedral elements, flash region is difficult to analyze because of the thin shape. In this paper, a hot…

Abstract

Purpose

In the finite element analysis of a hot forging process with hexahedral elements, flash region is difficult to analyze because of the thin shape. In this paper, a hot forging process is effectively analyzed by constructing a locally fine mesh in the flash region.

Design/methodology/approach

When remeshing is decided by an error estimation and flash is generated, the boundary patch of the mesh is constructed and expanded in the normal direction of the flash region. After hexahedral mesh is constructed in the expanded patch with master grid approach, the boundary patch is compressed to the original shape and the nodes in the boundary are moved to the relative position of the boundary patch. Then, a locally fine mesh is constructed in the flash region. The quality of mesh on the boundary is again improved by adding surface element layer. Therefore, the hot forging process can be effectively analyzed by constructing the adaptive hexahedral mesh in the flash region.

Findings

The results show that the locally fine mesh can be constructed in the hexahedral mesh generation procedure by constructing mesh in the expanded patch and compressing the mesh according to the original boundary patch without affecting the compatibility of element. Then, it is applied to the analysis of a hot forging process and it has been shown that the analysis result of the proposed technique can save the analysis time remarkably relative to that of the fine mesh, while maintaining the analysis accuracy of the fine mesh.

Originality/value

In the finite element analysis of a hot forging process, the flash region is very difficult to analyze because it is difficult to construct locally fine mesh with hexahedral elements. A new adaptive mesh generation technique using hexahedral elements is suggested to overcome such difficulty and applied to the analysis of a hot forging process.

Details

Engineering Computations, vol. 22 no. 2
Type: Research Article
ISSN: 0264-4401

Keywords

To view the access options for this content please click here
Article
Publication date: 2 March 2015

Roberto Raffaeli, Claudio Favi and Ferruccio Mandorli

High pressure die casting is a widely used industrial process to manufacture complex-shaped products in light alloys. Virtual prototyping techniques, especially…

Abstract

Purpose

High pressure die casting is a widely used industrial process to manufacture complex-shaped products in light alloys. Virtual prototyping techniques, especially numeric-based simulations of the casting process, allow the die filling process to be evaluated and help faster optimization of the gating system, which is the most critical element of the mould. The purpose of this paper is to present a four step approach to design optimal moulds taking advantage of the simulation tools.

Design/methodology/approach

No formalized method to design an optimal gating system is available yet and the majority of the studies aim to optimize existing geometries or to choose from alternative solutions. Rather than optimizing the geometries of predefined designs by running attempt trials, the proposed approach defines a procedure to position cavities, gating systems and, finally, to determine the whole mould geometry.

Findings

The approach is demonstrated through three different industrial applications. The design of a six-cavity mould for gas cooking burners is reported at first. Then, two test cases, a cup and a radiator, are reported for showing different arrangements of the gating system. The reached quality of the mould design has been assessed using metallographic analyses of the casts.

Originality/value

The design of a mould is strictly correlated to its product and mainly based on a trial-and-error approach. Numerical simulations offer a powerful and not expensive way to study the effectiveness of different die designs and filling processes. The paper proposes a structured approach for the definition of the gating system. It ultimately leads to improvements in both product quality and process productivity, including more effective control of the die filling and die thermal performance.

Details

Engineering Computations, vol. 32 no. 1
Type: Research Article
ISSN: 0264-4401

Keywords

To view the access options for this content please click here
Article
Publication date: 22 August 2008

Shumei Lou, Guoqun Zhao, Rui Wang and Xianghong Wu

The purpose of this paper is to find an efficient way by using finite volume method (FVM) to simulate the aluminum alloy profile extrusion processes.

Abstract

Purpose

The purpose of this paper is to find an efficient way by using finite volume method (FVM) to simulate the aluminum alloy profile extrusion processes.

Design/methodology/approach

By assuming isotropic conditions, the hot aluminum material is described as a non‐linear Newtonian fluid material. Semi‐implicit method for pressure‐linked equations algorithm is used to calculate the physical fields, and the dynamic viscosity is updated then. Volume of fluid method and moving grid method are also used for unsteady flow to catch the free surface of the material and the moving bound.

Findings

FVM model in this paper is an accurate and efficient method for the numerical simulation of aluminum profile extrusion processes. Compared with finite element method software, FVM model is both memory and CPU efficient.

Practical implications

Provide theoretical reference for sound extrusion process and die designs, which are the key factors to produce desirable products in industrial production.

Originality/value

The paper finds an efficient way to introduce the FVM in computational fluid dynamics field into the simulation of the steady and unsteady aluminum alloy profile extrusion processes. It provides a reference for people who are interested in FVM and extrusion processes.

Details

Engineering Computations, vol. 25 no. 6
Type: Research Article
ISSN: 0264-4401

Keywords

To view the access options for this content please click here
Article
Publication date: 5 April 2011

J.I.V. Sena, R.J. Alves de Sousa and R.A.F. Valente

Incremental sheet forming represents a promising process in the manufacturing of metallic components, particularly its variant known as single point incremental forming…

Abstract

Purpose

Incremental sheet forming represents a promising process in the manufacturing of metallic components, particularly its variant known as single point incremental forming (SPIF). The purpose of this paper is to test and validate the results coming from numerical simulation of SPIF processes using the reduced enhanced solid‐shell formulation, when compared to the solid finite elements available in ABAQUS software. The use of SPIF techniques in the production of small batch components has a potential wide application in fields such as rapid prototyping and biomechanical devices.

Design/methodology/approach

Incremental forming processes differ from conventional stamping by not using a press and by requiring a lower number of tools, since no dedicated punches and dies are necessary, which lowers the overall production costs. In addition, it shows relative simplicity and flexible setup for complex parts, when compared with conventional technologies. However, the low speed of production and low‐dimensional accuracy levels are still the main obstacles for a wider application of this technique in the context of large production batches.

Findings

In this sense, the use of numerical simulation tools based on the finite element method (FEM) can provide a better understanding of the process' peculiarities. However, there are differences on using distinct finite element formulations, regarding accuracy as well as CPU times during simulations, which can be prohibitive in some cases.

Originality/value

Aiming to provide sounding improvements in these two fields (robustness and cost effectiveness of FEM solutions), the present work encloses a preliminary study about some relevant parameters in the FEM simulation of SPIF. Special focus is given to the use of solid‐shell and solid finite elements, for the sake of generality in modelling, as well as implicit solution schemes for the sake of accuracy. Finally, results coming from both experimental data and commercial FEM packages are compared to those obtained by a reliable and cost‐effective solid‐shell finite element formulation developed and implemented by the authors.

Details

Engineering Computations, vol. 28 no. 3
Type: Research Article
ISSN: 0264-4401

Keywords

To view the access options for this content please click here
Article
Publication date: 4 November 2019

Sabah Khammass Hussein, Isam Tareq Abdullah and Abbas Khammas Hussein

The purpose of this paper is to join AA5052 to AISI 1006 steel sheets using the spot friction forming technique.

Abstract

Purpose

The purpose of this paper is to join AA5052 to AISI 1006 steel sheets using the spot friction forming technique.

Design/methodology/approach

A steel sheet was pre-holed with a diameter of 4.8 mm and pre-threaded with a single internal M6 thread. Lap joint configuration was used so that the aluminium specimen was put over steel. A rotating tool with a 10 mm diameter was used for the joining process. A Taguchi method was used to design three process parameters (plunging tool depth, rotating speed and preheating time), with three levels for each parameter. The effect of the process parameters on the joint shear strength was analysed. The macrostructure, microstructure and scanning electron microscope of the joint were investigated. The temperature distribution during the joining process was recorded.

Findings

The formed aluminium was extruded through the steel hole and penetrated through the thread slot. A mechanical interlock was achieved between the extruded aluminium and the steel. The plunging depth of the tool exhibited a significant effect on the joint shear strength. The joint efficiency increased gradually as the plunging depth increased. Two modes of failure were found shear and pull-out. The maximum temperature during the process reached 50 per cent of aluminium’s melting point.

Originality/value

For the first time, AA5052 was joined with AISI 1006 steel using a friction spot forming technique with an excellent joint efficiency.

Details

Multidiscipline Modeling in Materials and Structures, vol. 15 no. 6
Type: Research Article
ISSN: 1573-6105

Keywords

To view the access options for this content please click here
Article
Publication date: 12 November 2018

Mahesh S. Shinde, Kishor Mahadeorao Ashtankar, Abhaykumar M. Kuthe, Sandeep W. Dahake and Mahesh B. Mawale

This review paper aims to provide an overview of applications of direct rapid manufacturing assisted mold with conformal cooling channels (CCCs) and shows the potential of…

Abstract

Purpose

This review paper aims to provide an overview of applications of direct rapid manufacturing assisted mold with conformal cooling channels (CCCs) and shows the potential of this technique in different manufacturing processes.

Design/methodology/approach

Key publications from the past two decades have been reviewed.

Findings

This study concludes that direct rapid manufacturing technique plays a dominant role in the manufacturing of mold with complicated CCC structure which helps to improve the quality of final part and productivity. The outcome based on literature review and case study strongly suggested that in the near future direct rapid manufacturing method might become standard procedure in various manufacturing processes for fabrication of complex CCCs in the mold.

Practical implications

Advanced techniques such as computer-aided design, computer-aided engineering simulation and direct rapid manufacturing made it possible to easily fabricate the effective CCC in the mold in various manufacturing processes.

Originality/value

This paper is beneficial to study the direct rapid manufacturing technique for development of the mold with CCC and its applications in different manufacturing processes.

Details

Rapid Prototyping Journal, vol. 24 no. 8
Type: Research Article
ISSN: 1355-2546

Keywords

1 – 10 of 40