Search results

Fixture layout design is concerned with immobilization of the workpiece (engine mount bracket) during machining such that the workpiece elastic deformation is reduced. The fixture holds the workpiece through the positioning of fixturing elements that causes the workpiece elastic deformation, in turn, leads to the form and dimensional errors and increased machining cost. The fixture layout has the major impact on the machining accuracy and is the function of the fixturing position. The position of the fixturing elements, key aspects, needed to be optimized to reduce the workpiece elastic deformation. The purpose of this study is to evaluate the optimized fixture layout for the machining of the engine mount bracket.

In this research work, using the finite element method (FEM), a model is developed in the MATLAB for the fixture-workpiece system so that the workpiece elastic deformation is determined. The artificial neural network (ANN) is used to develop an empirical model. The results of deformation obtained for different fixture layouts from FEM are used to train the ANN and finally the empirical model is developed. The model capable of predicting the deformation is embedded to the evolutionary optimization techniques, capable of finding local and global optima, to optimize the fixture layouts and to find the robust one.

For efficient optimization of the fixture layout parameters to obtain the least possible deformation, ant colony algorithm (ACA) and artificial bee colony algorithm (ABCA) are used and the results of deformation obtained from both the optimization techniques are compared for the best results.

A MATLAB-based FEM technique is able to provide solutions when the repeated modeling and simulations required i.e. modeling of fixture layouts (500 layouts) for every variation in the parameters requires individual modeling and simulation for the output requirement in any FEM-based software’s (ANSYS, ABACUS). This difficulty is reduced in this research. So that the MATLAB-based FEM modeling, simulation and optimization is carried out to determine the solutions for the optimized fixture layout to reach least deformation.

Many a time the practicability of the machining/mechanical operations are difficult to perform costly and time-consuming when more number of experimentations are required. To sort out the difficulties the computer-based automated solution techniques are highly required. Such kind of research over this study is presented for the readers.

A MATLAB-based FEM modeling and simulation technique is used to obtain the fixture layout optimization. ANN-based empirical model is developed for the fixture layout deformation that creates a hypothesis for the fixture layout system. ACA and ABCA are used for optimizing the fixture layout parameters and are compared for the best algorithm suited for the fixture layout system.

The purpose of this paper is to propose a general model for locating and clamping workpieces of complex geometry with two skewed holes under multiple constraints.

Numerous constraints related to application of the proposed model are discussed as prerequisite to design of fixture solution. Based on theoretical model, a fixture was designed and successfully tested in experimental investigation. Experimental results were also verified using FEM simulations.

This study showed that, opposed to conventional approach, novel solution results in significantly smaller fixture dimensions, while providing greater stability. Insertion of mandrels and supports element sub-assemblies into the workpiece holes significantly increases workpiece stiffness through an increased moment of inertia, while the internal support elements largely diminish the problem of thin wall deformation in the workpiece.

The fixture designed in this case was actually used in industrial application to accommodate a thin-walled casting of gearbox housing, where it proved to be a very stable framework. It can be used in industry without any major readjustments.

According to available literature, this work is the first successful implementation of a fixture solution in which the problem of multiple constraints is solved by attaching centering elements, support sub-assemblies, and other fixture elements to the internal workpiece walls, and then locating them in the second part of the fixture.

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.

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.

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.

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.

Source errors in a workpiece fixture system include the compliance of the workpiece fixture system and workpiece dynamics. The purpose of this paper is to study the relative significance of these two. The findings would help to achieve computational economy in optimization of fixture layout and/or clamping forces.

Different layouts are generated with the help of a reconfigurable fixture set up and a slot is end milled on the workpiece. Using these data and the finite element software ANSYS, the machining error due to system compliance is computed. The machining error due to workpiece dynamics is obtained using a data acquisition system with the LabView software. These steps are repeated for different clamping forces and the relative contribution of these two sources to the overall machining error is studied.

Results show that the system compliance is much smaller in magnitude compared to workpiece dynamics and hence does not contribute appreciably to the overall machining error. This leads to the conclusion that, for bulky and stiff parts, evaluation of the machining error due to compliance can be done away with.

The paper's originality lies in comparing the two sources of machining error using experimental work and finite element models. To the author's knowledge such a comparison has not been reported in the literature.

Describes simulations of impact forging processes. Uses the explicit time integration finite element method, which is based on direct time integration of equation of motion, to compute the deformation of the workpiece and the dies. Uses the program developed to simulate the copper blow test performed on a 350,000J counter‐blow hammer. The calculated result reveals a good agreement in the final deformed configurations between the experiment and the explicit simulation. In order to compare this with the explicit method, the implicit time integration rigid‐plastic finite element program considering the inertia effect is also applied to the copper blow test simulation. As a result of the copper blow test simulation using the explicit program and the implicit program, finds that the calculated results have good agreements in available plastic deformation energy, forging load and equivalent plastic strain distribution. Finally, applies the developed program to simulations of multi‐blow forging processes. Presents three major findings from the multi‐blow forging simulations: (1) the continuous analysis technique used for the multi‐blow forging simulations works well; (2) the blow efficiency and the forging load generated by blow operations can be analysed efficiently and simulated results coincide with previous experimental and analytical ones; (3) the geometrical configuration of the workpiece is closely related to blow efficiency.

Near-net-shaped processes of jet engine blade have better performance in both reducing the material waste during production and improving work reliability in service, while the geometric features of blade, both sculptured surface and thin-walled shape, make the precise machining of blade challenging and difficult owing to its dynamics behaviors under complex clamping and machining loads. This paper aims to present a fundamental approach on modeling and performance analysis of the blade–fixture system.

A computerized framework on the complex blade–fixture dynamic behavior has been developed. Theoretical mechanic analysis on blade fixturing and machining is proposed with an especial emphasis on the boundary conditions of the blade–fixture system. Then the finite element analysis (FEA) method is used to simulate the variation trend of preloads, stiffness and blade distortion. The strong influence of parameters of workpiece–fixture configuration on blade distortion and machining error is investigated.

With a case of real jet engine blade machining, the experimental results and theoretical predictions suggest good agreement on their variation tendency. The loaded pressure of clamps has a critical influence on the total stiff performance of the blade–fixture system, and the profile error of the blade contributes much to the inconsistency in geometric dimension and surface integrity of blades’ machining. In the end, the results also validate the effectiveness of this methodology to predict and improve the performance of the blade–fixture configuration design.

The adaptive machining of near-net-shaped jet engine blade is a new high-performance manufacturing technology in aerospace production. This study provides a fundamental methodology for the performance analysis of blade-fixture system, to clear the variation law of blade distortion during preloading and machining, which will contribute to minimize the machining error and improve productivity.

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.

The friction stir welding (FSW) process comprises several highly coupled (and non‐linear) physical phenomena: large plastic deformation, material flow transportation, mechanical stirring of the tool, tool‐workpiece surface interaction, dynamic structural evolution, heat generation from friction and plastic deformation. This paper aims to present an advanced finite element (FE) model encapsulating this complex behaviour and various aspects associated with the FE model such as contact modelling, material model and meshing techniques are to be discussed in detail.

The numerical model is continuum solid mechanics‐based, fully thermo‐mechanically coupled and has successfully simulated the FSW process including plunging, dwelling and welding stages.

The development of several field variables are quantified by the model: temperature, stress, strain. Material movement is visualized by defining tracer particles at the locations of interest. The numerically computed material flow patterns are in very good agreement with the general findings from experiments.

The model is, to the best of the authors' knowledge, the most advanced simulation of FSW published in the literature.

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.

A synopsis is presented of the numerical finite element methodology currently in use at the Institute for Computer Applications (ICA) for the simulation of industrial forming processes. The development of the method is based on the inelastic properties of the material with an extension towards the inclusion of elastic effects and accounts for the thermal phenomena occurring in the course of the deformation. An essential constituent of the computational procedure is the treatment of the unsteady contact developing between the workpiece material and the tool during forming, and of the associated friction phenomena. Automatic mesh generation and variable discretization adaptable to the development of the numerical solution are of importance for industrial applications. These aspects are presented and discussed. Furthermore, solution techniques for thermomechanically coupled problems are considered and investigated with respect to their numerical properties. Application to industrial forming processes is demonstrated by means of three‐dimensional hot rolling and of superplastic sheet forming.