Search results for: forming limit curve

Authors: M. C. Cardoso, L. P. Moreira

Abstract:

In this work, the plastic behaviour of cold-rolled zinc coated dual-phase steel sheets DP600 and DP800 grades is firstly investigated with the help of uniaxial, hydraulic bulge and Forming Limit Curve (FLC) tests. The uniaxial tensile tests were performed in three angular orientations with respect to the rolling direction to evaluate the strain-hardening and plastic anisotropy. True stressstrain curves at large strains were determined from hydraulic bulge testing and fitted to a work-hardening equation. The limit strains are defined at both localized necking and fracture conditions according to Nakajima’s hemispherical punch procedure. Also, an elasto-plastic localization model is proposed in order to predict strain and stress based forming limit curves. The investigated dual-phase sheets showed a good formability in the biaxial stretching and drawing FLC regions. For both DP600 and DP800 sheets, the corresponding numerical predictions overestimated and underestimated the experimental limit strains in the biaxial stretching and drawing FLC regions, respectively. This can be attributed to the restricted failure necking condition adopted in the numerical model, which is not suitable to describe the tensile and shear fracture mechanisms in advanced high strength steels under equibiaxial and biaxial stretching conditions.

Keywords: Advanced high strength steels, forming limit curve, numerical modeling, sheet metal forming.

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Authors: Hossein Mamusi, Abolfazl Masoumi, Ramezanali Mahdavinezhad

Abstract:

Tailor-welded Blanks (TWBs) are tailor made for different complex component designs by welding multiple metal sheets with different thicknesses, shapes, coatings or strengths prior to forming. In this study the Hemispherical Die Stretching (HDS) test (out-of-plane stretching) of TWBs were simulated via ABAQUS/Explicit to obtain the Forming Limit Diagrams (FLDs) of Stainless steel (AISI 304) laser welded blanks with different thicknesses. Two criteria were used to detect the start of necking to determine the FLD for TWBs and parent sheet metals. These two criteria are the second derivatives of the major and thickness strains that are given from the strain history of simulation. In the other word, in these criteria necking starts when the second derivative of thickness or major strain reaches its maximum. With having the time of onset necking, one can measure the major and minor strains at the critical area and determine the forming limit curve.

Keywords: TWB, Forming Limit Diagram, Necking criteria, ABAQUS/Explicit

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Authors: M. Mahboubkhah, H. Fayazfar

Abstract:

In this research, Forming Limit Diagrams for supertension sheet metals which are using in automobile industry have been obtained. The exerted strains to sheet metals have been measured with four different methods and the errors of each method have also been represented. These methods have been compared with together and the most efficient and economic way of extracting of the exerted strains to sheet metals has been introduced. In this paper total error and uncertainty of FLD extraction procedures have been derived. Determination of the measurement uncertainty in extracting of FLD has a great importance in design and analysis of the sheet metal forming process.

Keywords: Forming Limit Diagram, Major and Minor Strain, Measurement Uncertainty.

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Authors: Basavaraj Vadavadagi, Satishkumar Shekhawat

Abstract:

Interstitial free steels possess better formability and have many applications in automotive industries. Forming limit diagrams (FLDs) indicate the formability of materials which can be determined by experimental and finite element (FE) simulations. FLDs were determined experimentally by LDH test, utilizing optical strain measurement system for measuring the strains in different width specimens and by FE simulations in Interstitial Free (IF) and Interstitial Free High Strength (IFHS) steels. In this study, the experimental and FE simulated FLDs are compared and also the stress based FLDs were investigated.

Keywords: Forming limit diagram, Limiting Dome Height, optical strain measurement, interstitial

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Authors: Ching-Shoei Chiang, Sheng-Hsin Tsai, James Chen

Abstract:

The PH curve can be constructed by given parameters, but the shape of the curve is not so easy to image from the value of the parameters. On the contract, Bézier curve can be constructed by the control polygon, and from the control polygon, we can image the figure of the curve. In this paper, we want to use the hodograph of Bézier curve to construct PH curve by selecting part of the control vectors, and produce other control vectors, so the property of PH curve exists.

Keywords: PH curve, hodograph, Bézier curve.

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Authors: K. Rattanachan

Abstract:

In sheet metal forming process, raw material mechanical properties are important parameters. This paper is to compare the wall’s incline angle or formability of SS 400 steel and SUS 304 stainless steel in single point incremental forming. The two materials are ferrous base alloyed, which have the different unit cell, mechanical property and chemical composition. They were forming into cone shape specimens having 100 mm diameter with different wall’s incline angle: 90o, 75o and 60o. The investigation was continued until the specimens formed surface facture. The experimental result showed that the smaller the wall incline angle higher the formability with the both materials. The formability limit of the ferrous base alloy was approx. 60o wall’s incline angle. By nature, SS 400 has higher formability than SUS 304. This result can be used as the initial data in designing the single point incremental forming parts.

Keywords: NC incremental forming, Single point incremental forming, Wall incline angle, Formability.

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Authors: Ashok Ganguly, Pranjali Arondekar

Abstract:

In the present paper, we use generalized B-Spline curve in trigonometric form on circular domain, to capture the transcendental nature of circle involute curve and uncertainty characteristic of design. The required involute curve get generated within the given tolerance limit and is useful in gear design.

Keywords: Bézier, Circle Involute, NAUT B-Spline, Spur Gear.

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Authors: Lívia B. Meirelles, Erika C. A. N. Chrisman, Flávia B. de Andrade, Lilian C. M. de Oliveira

Abstract:

True Boiling Point distillation (TBP) is one of the most common experimental techniques for the determination of petroleum properties. This curve provides information about the performance of petroleum in terms of its cuts. The experiment is performed in a few days. Techniques are used to determine the properties faster with a software that calculates the distillation curve when a little information about crude oil is known. In order to evaluate the accuracy of distillation curve prediction, eight points of the TBP curve and specific gravity curve (348 K and 523 K) were inserted into the HYSYS Oil Manager, and the extended curve was evaluated up to 748 K. The methods were able to predict the curve with the accuracy of 0.6%-9.2% error (Software X ASTM), 0.2%-5.1% error (Software X Spaltrohr).

Keywords: Distillation curve, petroleum distillation, simulation, true boiling point curve.

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Authors: Eshwara K. Prasad, Raman R. Goud, Swadesh Kumar Singh, N. Sateesh

Abstract:

In the present work, forming limit diagrams and strain distribution profile diagrams for extra deep drawing steel at room and elevated temperatures have been determined experimentally by conducting stretch forming experiments by using designed and fabricated warm stretchforming tooling setup. With the help of forming Limit Diagrams (FLDs) and strain, distribution profile diagrams the formability of Extra Deep Drawing steel has been analyzed and co-related with mechanical properties like strain hardening COEFFICIENT (n) and normal anisotropy (r−). Mechanical properties of EDD steel from room temperature to 4500C were determined and discussed the impact of temperature on the properties like work hardening exponent (n) anisotropy (r-) and strength coefficient of the material. In addition, the fractured surfaces after stretching have undergone the some metallurgical investigations and attempt has been made to co-relate with the formability of EDD steel sheets. They are co-related and good agreement with FLDs at various temperatures.

Keywords: FLD, microhardness, strain distribution profile, stretch forming.

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Authors: R. Alipour, F.Najarian

Abstract:

Because of high ductility, aluminum alloys, have been widely used as an important base of metal forming industries. But the main week point of these alloys is their low strength so in forming them with conventional methods like deep drawing, hydro forming, etc have been always faced with problems like fracture during of forming process. Because of this, recently using of explosive forming method for forming of these plates has been recommended. In this paper free explosive forming of A2024 aluminum alloy is numerically simulated and during it, explosion wave propagation process is studied. Consequences of this simulation can be effective in prediction of quality of production. These consequences are compared with an experimental test and show the superiority of this method to similar methods like hydro forming and deep drawing.

Keywords: Free explosive forming, CEL, Johnson cook.

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Authors: Mat Syai'in, Adi Soeprijanto, Takashi Hiyama

Abstract:

An optimal power flow (OPF) based on particle swarm optimization (PSO) was developed with more realistic generator security constraint using the capability curve instead of only Pmin/Pmax and Qmin/Qmax. Neural network (NN) was used in designing digital capability curve and the security check algorithm. The algorithm is very simple and flexible especially for representing non linear generation operation limit near steady state stability limit and under excitation operation area. In effort to avoid local optimal power flow solution, the particle swarm optimization was implemented with enough widespread initial population. The objective function used in the optimization process is electric production cost which is dominated by fuel cost. The proposed method was implemented at Java Bali 500 kV power systems contain of 7 generators and 20 buses. The simulation result shows that the combination of generator power output resulted from the proposed method was more economic compared with the result using conventional constraint but operated at more marginal operating point.

Keywords: Optimal Power Flow, Generator Capability Curve, Particle Swarm Optimization, Neural Network

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Authors: Esther T. Akinlabi, Mukul Shukla, Stephen A. Akinlabi

Abstract:

Laser beam forming is a novel technique developed for the joining of metallic components. In this study, an overview of the laser beam forming process, areas of application, the basic mechanisms of the laser beam forming process, some recent research studies and the need to focus more research effort on improving the laser-material interaction of laser beam forming of titanium and its alloys are presented.

Keywords: Aerospace, Deformation, Laser forming, Mechanisms, Titanium, Titanium alloy.

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Authors: Petr Homola, Lucie Novakova, Vaclav Kafka, Mariluz P. Oscoz

Abstract:

Shear spinning is closely related to the asymmetric incremental sheet forming (AISF) that could significantly reduce costs incurred by the fabrication of complex aeronautical components with a minimal environmental impact. The spinning experiments were carried out on commercially pure titanium (Ti-Gr2) and Ti-6Al-4V (Ti-Gr5) alloy. Three forming modes were used to characterize the titanium alloys properties from the point of view of different spinning parameters. The structure and properties of the materials were assessed by means of metallographic analyses and microhardness measurements. The highest value wall angle failure limit was achieved using spinning parameters mode for both materials. The feed rate effect was observed only in the samples from the Ti-Gr2 material, when a refinement of the grain microstructure with lower feed rate and higher tangential speed occurred. Ti-Gr5 alloy exhibited a decrease of the microhardness at higher straining due to recovery processes.

Keywords: Incremental forming, metallography, shear spinning, titanium alloys.

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Authors: Maziar Ramezani, Thomas Neitzert, Timotius Pasang

Abstract:

This paper aims at experimental and numerical investigation of springback behavior of sheet metals during L-bending process with emphasis on Stribeck-type friction modeling. The coefficient of friction in Stribeck curve depends on sliding velocity and contact pressure. The springback behavior of mild steel and aluminum alloy 6022-T4 sheets was studied experimentally and using numerical simulations with ABAQUS software with two types of friction model: Coulomb friction and Stribeck friction. The influence of forming speed on springback behavior was studied experimentally and numerically. The results showed that Stribeck-type friction model has better results in predicting springback in sheet metal forming. The FE prediction error for mild steel and 6022-T4 AA is 23.8%, 25.5% respectively, using Coulomb friction model and 11%, 13% respectively, using Stribeck friction model. These results show that Stribeck model is suitable for simulation of sheet metal forming especially at higher forming speed.

Keywords: Friction, L-bending, Springback, Stribeck curves.

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Authors: M. Y. Misro, A. Ramli, J. M. Ali

Abstract:

Bezier curves have useful properties for path generation problem, for instance, it can generate the reference trajectory for vehicles to satisfy the path constraints. Both algorithms join cubic Bezier curve segment smoothly to generate the path. Some of the useful properties of Bezier are curvature. In mathematics, curvature is the amount by which a geometric object deviates from being flat, or straight in the case of a line. Another extrinsic example of curvature is a circle, where the curvature is equal to the reciprocal of its radius at any point on the circle. The smaller the radius, the higher the curvature thus the vehicle needs to bend sharply. In this study, we use Bezier curve to fit highway-like curve. We use different approach to find the best approximation for the curve so that it will resembles highway-like curve. We compute curvature value by analytical differentiation of the Bezier Curve. We will then compute the maximum speed for driving using the curvature information obtained. Our research works on some assumptions; first, the Bezier curve estimates the real shape of the curve which can be verified visually. Even though, fitting process of Bezier curve does not interpolate exactly on the curve of interest, we believe that the estimation of speed are acceptable. We verified our result with the manual calculation of the curvature from the map.

Keywords: Speed estimation, path constraints, reference trajectory, Bezier curve.

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Authors: Sol-Kil Oh, Hye-Jin Lee, Jung-Han Song, Kyoung-Tae Kim, Nak-Kyu Lee, Jong-Ho Kim

Abstract:

This paper deals with a novel technique for the fabrication of Spiral grooves in a dynamic thrust bearing. The main scheme proposed in this paper is to fabricate the microgrooves using desktop forming system. This process has advantages compared to the conventional electro-chemical machining in the viewpoint of a higher productivity. For this reason, a new testing apparatus is designed and built for press forming microgrooves on a surface of the thrust bearing. The material used in this study is sintered Cu-Fe alloy. The effects of the forming load on the performance of micro press forming are experimentally investigated. From the experimental results, formed depths are closed to the target ones with increasing the forming load.

Keywords: Desktop forming system, Fluid dynamic bearing, Thrust bearing, Microgroove.

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Authors: Hongyu Wei, Wenliang Chen, Lin Gao

Abstract:

Incremental forming is a complex forming process with continuously local cumulative deformation taking place during its process, and springback that forming quality affected by would occur. The springback evaluation method based on forming error compensation also was proposed, which it can be defined as the difference between theory and the actual amount of compensation along the measured direction. According to forming error compensation evaluation method, experiments was designed and implemented. And from the results that obtained it can be show, the magnitude of springback average (δE) of formed parts was very small, and the forming precision could be significantly improved by adopting compensation method. Based on double tensile stress state in the main deformation area, a hypothesis that there is little springback be arisen by bending behavior on the formed parts that was proposed.

Keywords: Sheet metal, incremental forming, springback, forming error compensation, geometric accuracy

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Authors: P. Sawitri, S. Cdr. Sittha, T. Kritsana

Abstract:

Flow forming is widely used in many industries, especially in defence technology industries. Pressure vessels requirements are high precision, light weight, seamless and optimum strength. For large pressure vessels, flow forming by 3 rollers machine were used. In case of long range rocket motor case flow forming and welding of pressure vessels have been used for manufacturing. Due to complication of welding process, researchers had developed 4 meters length pressure vessels without weldment by 4 rollers flow forming machine. Design and preparation of preform work pieces are performed. The optimization of flow forming parameter such as feed rate, spindle speed and depth of cut will be discussed. The experimental result shown relation of flow forming parameters to quality of flow formed tube and prototype pressure vessels have been made.

Keywords: Flow forming, Pressure vessel, four rollers, feed rate, spindle speed, cold work.

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Authors: Dae-Hee Son, Seung-Hwa Kang, Sang-Hee Kang, Soon-Ryul Nam

Abstract:

Wind farms usually produce power irregularly, due to  unpredictable change of wind speed. Accordingly, we should  determine the penetration limit of wind power to consider stability of  power system and build a facility to control the wind power. The  operational limit of wind power is determined as the minimum  between the technical limit and the dynamic limit of wind power. The  technical limit is calculated by the number of generators and the  dynamic limit is calculated by the constraint of frequency variation  when a wind farm is disconnected suddenly. According to the  determined operational limit of wind power, pitch angles of wind  generators are controlled. PSS/E simulation results show that the pitch  angles were correctly controlled when wind speeds are changed in  addition to loads.

Keywords: Pitch Angle, Dynamic limit, Operational limit, Technical limit.

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Authors: S. H. Yahaya, J. M. Ali, T.A. Abdullah

Abstract:

The exploration of this paper will focus on the Cshaped transition curve. This curve is designed by using the concept of circle to circle where one circle lies inside other. The degree of smoothness employed is curvature continuity. The function used in designing the C-curve is Bézier-like cubic function. This function has a low degree, flexible for the interactive design of curves and surfaces and has a shape parameter. The shape parameter is used to control the C-shape curve. Once the C-shaped curve design is completed, this curve will be applied to design spur gear tooth. After the tooth design procedure is finished, the design will be analyzed by using Finite Element Analysis (FEA). This analysis is used to find out the applicability of the tooth design and the gear material that chosen. In this research, Cast Iron 4.5 % Carbon, ASTM A-48 is selected as a gear material.

Keywords: Bézier-like cubic function, Curvature continuity, Cshapedtransition curve, Spur gear tooth.

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Authors: Abouzar Nasiri, Hamid Alipur

Abstract:

In recent years, geographic information systems (GIS) and remote sensing using has increased to estimate runoff catchment. In this research, runoff curve number maps for captive catchment of Tehran by helping GIS and also remote sensing which based on factors such as vegetation, lands using, group of soil hydrology and hydrological conditions were obtained. Runoff curve numbers map was obtained by combining these maps in ARC GIS and SCS table. To evaluate the accuracy of the results, the maximum flow rate of flood which was obtained from curve numbers, was compared with the measured maximum flood rate at the watershed outlet and correctness of curve numbers were approved.

Keywords: Curve number, GIS, Remote sensing, Runoff.

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Authors: Morteza Khaleghi, Babak Seyed Aghazadeh, Hosein Bisadi

Abstract:

Oxyhydrogen is a mixture of Hydrogen (H₂) and Oxygen (O₂) gases. Detonative mixtures of oxyhydrogens with various combinations of these two gases were used in Gas Detonation Forming (GDF) to form sheets of mild steel. In die forming experiments, three types of conical dies with apex angles of 60, 90 and 120 degrees were used. Pressure of mixtures inside the chamber before detonation was varied from 3 Bar to 5 Bar to investigate the effect of pre-detonation pressure in the forming process. On each conical die, several experiments with different percentages of Hydrogen were carried out to determine the optimum gaseous mixture. According to our results the best forming process occurred when approximately 50-70%. Hydrogen was employed in the mixture. Furthermore, the experimental results were compared to the ones from FEM analysis. The FEM simulation results of thickness strain, hoop strain, thickness variation and deformed geometry are promising.

Keywords: Sheet metal forming, Gas detonation, FEM, Oxyhydrogen

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Authors: Gizem Intepe, Tufan Koc

Abstract:

S-Curves are commonly used in technology forecasting. They show the paths of product performance in relation to time or investment in R&D. It is a useful tool to describe the inflection points and the limit of improvement of a technology. Companies use this information to base their innovation strategies. However inadequate use and some limitations of this technique lead to problems in decision making. In this paper first technology forecasting and its importance for company level strategies will be discussed. Secondly the S-Curve and its place among other forecasting techniques will be introduced. Thirdly its use in technology forecasting will be discussed based on its advantages, disadvantages and limitations. Finally an application of S-curve on 3D TV technology using patent data will also be presented and the results will be discussed.

Keywords: Patent analysis, Technological forecasting. S curves, 3D TV

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Authors: A. Bendarma, T. Jankowiak, A. Rusinek, T. Lodygowski, M. Klósak, S. Bouslikhane

Abstract:

The analysis of the mechanical characteristics and dynamic behavior of aluminum alloy sheet due to perforation tests based on the experimental tests coupled with the numerical simulation is presented. The impact problems (penetration and perforation) of the metallic plates have been of interest for a long time. Experimental, analytical as well as numerical studies have been carried out to analyze in details the perforation process. Based on these approaches, the ballistic properties of the material have been studied. The initial and residual velocities laser sensor is used during experiments to obtain the ballistic curve and the ballistic limit. The energy balance is also reported together with the energy absorbed by the aluminum including the ballistic curve and ballistic limit. The high speed camera helps to estimate the failure time and to calculate the impact force. A wide range of initial impact velocities from 40 up to 180 m/s has been covered during the tests. The mass of the conical nose shaped projectile is 28 g, its diameter is 12 mm, and the thickness of the aluminum sheet is equal to 1.0 mm. The ABAQUS/Explicit finite element code has been used to simulate the perforation processes. The comparison of the ballistic curve was obtained numerically and was verified experimentally, and the failure patterns are presented using the optimal mesh densities which provide the stability of the results. A good agreement of the numerical and experimental results is observed.

Keywords: Aluminum alloy, ballistic behavior, failure criterion, numerical simulation.

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Authors: Safa Boudhaouia, Mohamed Amen Gahbiche, Eliane Giraud, Wacef Ben Salem, Philippe Dal Santo

Abstract:

Multi-point forming (MPF) and asymmetric incremental forming (ISF) are two flexible processes for sheet metal manufacturing. To take advantages of these two techniques, a hybrid process has been developed: The Multipoint Incremental Forming (MPIF). This process accumulates at once the advantages of each of these last mentioned forming techniques, which makes it a very interesting and particularly an efficient process for single, small, and medium series production. In this paper, an experimental and a numerical investigation of this technique are presented. To highlight the flexibility of this process and its capacity to manufacture standard and complex shapes, several pieces were produced by using MPIF. The forming experiments are performed on a 3-axis CNC machine. Moreover, a numerical model of the MPIF process has been implemented in ABAQUS and the analysis showed a good agreement with experimental results in terms of deformed shape. Furthermore, the use of an elastomeric interpolator allows avoiding classical local defaults like dimples, which are generally caused by the asymmetric contact and also improves the distribution of residual strain. Future works will apply this approach to other alloys used in aeronautic or automotive applications.

Keywords: Incremental forming, numerical simulation, MPIF, multipoint forming.

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Authors: Zhiguo Ren, Lilong Cai

Abstract:

This paper present an effective method to accurately reconstruct and measure the 3D curve edges of small industrial parts based on stereo vision. To effectively fit the curve of the measured parts using a series of line segments in the images, a strategy from coarse to fine is employed based on multi-scale curve fitting. After reconstructing the 3D curve of a hole through a curved surface, its axis is adjusted so that it is parallel to the Z axis with least squares error and the dimensions of the hole can be calculated on the XY plane easily. Experimental results show that the presented method can accurately measure the dimensions of round holes through a curved surface.

Keywords: Stereo Vision, 3D Round Hole Measurement, Curve Fitting, 3D Curve Reconstruction, Least Squares Error.

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Authors: M. Hassani, Y. Hassani, N. Ajudanioskooei, N. N. Benvid

Abstract:

Laser Forming process as a non-contact thermal forming process is widely used to forming and bending of metallic and non-metallic sheets. In this process, according to laser irradiation along a specific path, sheet is bent. One of the most important output parameters in laser forming is bending angle that depends on process parameters such as physical and mechanical properties of materials, laser power, laser travel speed and the number of scan passes. In this paper, Artificial Neural Network and Fuzzy Logic System were used to predict of bending angle in laser forming process. Inputs to these models were laser travel speed and laser power. The comparison between artificial neural network and fuzzy logic models with experimental results has been shown both of these models have high ability to prediction of bending angles with minimum errors.

Keywords: Artificial neural network, bending angle, fuzzy logic, laser forming.

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Authors: Shunsuke Miyoshi, Yasuyuki Nogami, Takuya Kusaka, Nariyoshi Yamai

Abstract:

Elliptic curve discrete logarithm problem(ECDLP) is one of problems on which the security of pairing-based cryptography is based. This paper considers Pollard’s rho method to evaluate the security of ECDLP on Barreto-Naehrig(BN) curve that is an efficient pairing-friendly curve. Some techniques are proposed to make the rho method efficient. Especially, the group structure on BN curve, distinguished point method, and Montgomery trick are well-known techniques. This paper applies these techniques and shows its optimization. According to the experimental results for which a large-scale parallel system with MySQL is applied, 94-bit ECDLP was solved about 28 hours by parallelizing 71 computers.

Keywords: Pollard’s rho method, BN curve, Montgomery multiplication.

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Authors: Fakharuddin Ibrahim, Jamaludin Md. Ali, Ahmad Ramli

Abstract:

In this paper, we will discuss about the data interpolation by using the rational cubic Ball curve. To generate a curve with a better and satisfactory smoothness, the curve segments must be connected with a certain amount of continuity. The continuity that we will consider is of type G¹ continuity. The conditions considered are known as the G¹ Hermite condition. A simple application of the proposed method is to generate an Arabic font satisfying the required continuity.

Keywords: Continuity, data interpolation, Hermite condition, rational Ball curve.

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Authors: Amir Ansari, Ehsan Shahrjerdi, Ehsan Amini

Abstract:

To investigate the behavior of sheet metals during forming tailor welded blanks (TWB) of various thickness made via Co2 Laser welding are under consideration. These blanks are formed used two different forming methods of rubber as well as the conventional punch and die methods. The main research objective is the effects of using a rubber die instead of a solid one the displacement of the weld line and the press force needed for forming. Specimens with thicknesses of 0.5, 0.6, 0.8 and 1mm are subjected to Erichsen two dimensional tests and the resulted force for each case are compared. This is followed by a theoretical and numerical study of press force and weld line displacement. It is concluded that using rubber pad forming (RPF) causes a reduction in weld line displacement and an increase in the press force.

Keywords: Rubber pad forming, Tailor welded blank, Thickness ratio, Weld line displacement.

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