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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 them to…

1954

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

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…

4528

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

Content available
Book part
Publication date: 6 November 2023

Abstract

Details

Higher Education in Emergencies: International Case Studies
Type: Book
ISBN: 978-1-83797-345-3

Book part
Publication date: 6 November 2023

Ahmad Samarji and Reem Ghaddar

Since the declaration of COVID-19 as a pandemic in March 2020, higher education institutions (HEIs) across the globe have shifted – entirely or partly – to online teaching and…

Abstract

Since the declaration of COVID-19 as a pandemic in March 2020, higher education institutions (HEIs) across the globe have shifted – entirely or partly – to online teaching and learning; Lebanese HEIs were no exception. Such an unprecedented and “forced” transition to online teaching and learning has created a landscape for scholars and researchers to inquire into the efficiency and effectiveness of online teaching and learning, students’ satisfaction with this virtual educational experience, and instructors’ satisfaction with such an experience. This chapter presents a study about Lebanese instructors’ satisfaction with online teaching and learning during the pandemic. Instructors’ satisfaction was measured in terms of three satisfaction constructs of psychometrically validated “Online Instructor Satisfaction Measure” (OISM): instructor-to-student interaction (ISI); student-to-student interaction (SSI); and course design, development, and teaching (CDT). Data were collected through an online questionnaire from 102 Lebanese instructors across 7 Lebanese universities: 6 private universities and the national public Lebanese higher education institute (Lebanese University). This study found that there were no significant changes between the satisfaction levels in relation to each of the ISI, SSI, and CDT constructs between STEM education background instructors and their non-STEM education background counterparts. Despite their dissatisfaction with the level of interaction between them and their students (ISI), the participating Lebanese instructors were satisfied with the SSI, except for students’ collaborative and group work, and were also satisfied with the CDT, except for the preparation time required for delivering an online course.

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…

1437

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

Open Access
Article
Publication date: 14 June 2021

Vennan Sibanda, Khumbulani Mpofu and John Trimble

In manufacturing, dedicated machine tools and flexible machine tools are failing to satisfy the ever-changing manufacturing demands of short life cycles and dynamic nature of…

1881

Abstract

Purpose

In manufacturing, dedicated machine tools and flexible machine tools are failing to satisfy the ever-changing manufacturing demands of short life cycles and dynamic nature of products. These machines are limited when new product designs are introduced. The solution lies in developing responsive machines that can be adjusted or be changed functionally when these change requirements arise. These machines are reconfigurable machines which are becoming the new focus, as they rapidly respond to product variety and volume changes. A sheet metal working machine known as a reconfigurable guillotine shear and bending press machine (RGS&BPM) has been developed. The purpose of this paper is to present a methodology, function-oriented design approach (FODA), which was developed for the design of the RGS&BPM.

Design/methodology/approach

The design of the machine is based on the six principles of reconfigurable manufacturing systems (RMSs), namely, modularity, scalability integrability, convertibility, diagnosability and customisability. The methodology seeks to optimise the design process of the RGS&BPM through a design of modules that make up the machine, enable its conversion and reconfiguration. The FODA is focussed on function identification to select the operational function required. Two main functions are recognised for the machine, these being cutting and bending; hence, the design revolves around these two and reconfigurability.

Findings

The developed design methodology was tested in the design of a prototype for the reconfigurable guillotine shear and bending press machine. The prototype is currently being manufactured and will be subjected to functional tests once completed. This paper is being presented not only to present the methodology by to show and highlight its practical applicability, as the prototype manufacturers have been enthusiastic about this new approach.

Research limitations/implications

The research was limited to the design methodology for the RGS&BPM, the machine which has been designed to completion using this methodology, with prototype being manufactured.

Practical implications

This study presents critical steps and considerations in the development of reconfigurable machines. The main thrust being to explore the best possibility of developing the machines with dual functionality that will assist in availing the technology to manufacturer. As the machine has been development, the success of the design can be directly attributed to the FODA methodology, among other contributing factors. It also highlights the significance of the principles of RMS in reconfigurable machine design.

Social implications

The RGS&BM machine is an answer for the small-to-medium enterprises (SMEs), as the machine replaces two machines with one, and the methodology ensures its affordable design. It contributes immensely to the machine availability by eliminating trial and error approaches.

Originality/value

This study presents a new approach to the design of reconfigurable dual machines using principles of RMS. As the targeted market is the SME, it is not limited to that as any entrepreneur may use the machine to their advantage. The design methodology presented contributes to the body of knowledge in dual reconfigurable machine tool design.

Details

Journal of Engineering, Design and Technology , vol. 19 no. 6
Type: Research Article
ISSN: 1726-0531

Keywords

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 remeshing…

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

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 forging…

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

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 numeric-based…

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

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

1 – 10 of 55