CAE Modeling Research Articles

Горячее деформирование корпусных заготовок в изотермических условиях

Core operations with hollow products, having a periodically changing internal profile, consists in the final machining of press forgings. However, at the same time, metal rejects are high, and despite the high quality of the products obtained, their mechanical characteristics do not always meet the requirements of functioning. For the equipment units, when subjected to heavy loads, the parts are usually made of high-strength materials. Due to the complexity of the work on a workpieces made of high-strength alloys, operations are carried out with heating of the deformed zone of the in-process part or with a total heating. The use of slow deformation in the hot state under certain speed conditions is promising. The process of the internal pattern formation for hollow shells made of titanium alloy VT6 is viewed. These products are mainly used as various airframes and are made using special methods of mechanical engineering. Due to the use of high-strength billet materials, there are difficulties with the mechanization of the production methods. The article evaluates force conditions for generation of geometry on the shells based on CAE modeling. The simulation was performed in the deform complex. The focus of the research was on the assessment of deformation forces and stress intensities. The influence of deformation ratio, strain rates, punch geometry on the strength of the process and stress intensity has been revealed. A regression equation to estimate the forces of the process is deduced. Recommendations on the design of fillets forming operations have been obtained. Deformation modes aimed at achieving rational power modes, respectively, loads on the tool, which indirectly affects its durability, as well as the stress condition in the product, have been found.

Disembarkation of a bar titanium billet in the mode of slow flow of the material

The results of CAE modeling of the process of forming an element of a titanium bar billet under hot die forging conditions are presented. Calculations of deformation of bar billets with different sections at different tool rates are presented. The upsetting forces, the stressed state in critical areas of the billet, and the parameters of the deformation process are analyzed. The dependences of the indicators of the stress-strain state of the billet on the rate and force of deformation are obtained. Keywords:upsetting, force, deformation, forming, stress, modeling sulee@mail.ru

Изотермическая высадка титановых прутковых заготовок пуансоном с косой рабочей поверхностью

The operation of obtaining cylindrical products with a titling pad made of titanium alloy VT6 is viewed in the article. The operation involves impacting a bar blank made of titanium alloy VT6 with the use of a punch having sloped edge. When obtaining parts having titling pad made of difficult-to-form alloys, it is necessary to formulate the modes of technology. It is required to specify the rates of deformation and the impact of contact friction on the kinematics of the material flow and the force of shape change to assess the capabilities of the process performed by CAE modeling. Therefore, the simulation of obtaining cylindrical products with a titling pad made of titanium alloy VT6 was performed in the DEFORM modeling program. The influence of the speed conditions of the operation on the change in the values of stress intensities in the product was found. The dependences of the influence of the angles and rates of deformation on the landing force are revealed. The results of theoretical studies obtained during the simulation were summarized. A regression analysis of the results obtained during the simulation was performed. Based on the simulation results, expressions for estimating the intensity of stresses are obtained. The results of regression modeling are in good agreement with the results of computer modeling. Using quantitative modeling results, a regression assessment of the force was taken. Regression equations in natural values are obtained for the assessment of the impact of key process parameters during setup, which can be useful directly when assigning technological modes of titanium alloy blanks setup. The results can be used in the implementation of manufacturing technologies for parts with flange seals, characterized by the best strength characteristics and good load resistance.

Investigation of the Processes Occurring During the Operation of the Torque Converter Hub in the Belarusian Autoworks Gearbox during CAE Modeling

The main objective of the study is to identify and eliminate the causes of breakdowns in the torque converter hubs of mining dump trucks Belarusian Autoworks. The relevance of the work carried out: during the operation of dump trucks based on Belarusian Autoworks vehicles, in open pit conditions, according to enterprises operating such equipment, in the period from 2019 to 2021, 75% of the failures and breakdowns of equipment occurred due to the fact that the hub of the torque converter impeller is intensively loaded a part, which during its operation is affected not only by mechanical loads, but also by temperature and others leading to the failure of the specified unit in 85% of cases. For example, hydrodynamic forces that arise during the period of immersion of gear teeth in an oil bath, and so on. Therefore, it is proposed to conduct a comprehensive study of the processes occurring with the wheel hub and identify the main loaded places. Taking into account the analysis carried out, it is possible to produce a batch of wheel hubs with updated parameters and conduct their full-scale tests. The novelty of the work carried out lies in the analysis of the operating conditions of the hub, which revealed a high boundary pressure that occurs at the point of transition from the air to the oil bath. The object of research is the study of the processes that occur during the operation of the torque converter hub, which affect the structure and occur in the hub itself. Research objectives: - learn the ways and methods of conducting CAE analysis; - analyze the design parameters of the installation that occur in the torque converter bushing. Research methods: When performing the dissertation work, methods of physical and mathematical modeling and system analysis of information, laboratory, bench and operational tests using computer and high-precision measuring equipment were used

A Fully Mechanical Realization of PID Controller

PID controller is one of the most widely used control elements in the industry. Over history, people have implemented the PID controller mechanically with pneumatical components, electronically in circuits, or digitally using DSP. However, the pure mechanical realization of PID controllers is rarely studied. This paper presents an analog PID controller based on mechanical computation components, including a mechanical integrator, a mechanical differentiator, mechanical constant multipliers, and a mechanical adder. In this work, those parts are studied respectively with CAE modeling and mathematical derivation. A novel design of mechanical differentiator is also introduced to conduct the calculation of the differential part on the PID controller. This work explores the theoretical possibility of a new form of PID controller realization, that is, applying the method of mechanical analog computation to the implementation of a PID controller.

Research on 3D reconstruction technology of microscopic pore defects in cast steel

Affected by the production process, microscopic pore defects are inevitably distributed in steel castings. The existence of microscopic defects affects the macroscopic mechanical properties of steel castings. The numerical analysis of finite element model with microscopic pore defects is one of the effective ways to reveal the influence of microscopic defects on failure and fracture of steel castings. However, the spatial morphology of microscopic pore defects in cast steel is extremely complex, so the traditional CAE modeling method cannot meet the accuracy requirements. This article was inspired by the idea of reverse modeling in the medical field. Based on the 3D X-ray tomography data of G20Mn5N cast steel specimens, 3D models of microscopic pore defects with complex spatial morphology were reconstructed. Finite element analysis was performed in representative volume elements (RVE) model to study the effect of microscopic pore defects characteristics on the mechanical properties of cast steel.

CAE Modeling Rubber-metal Body Mounting of the Body-on-frame Car in Crash Simulations

The aim of the study was to research the behavior of the rubber-metal body mounting under various modeling options and to select the optimal, from the point of view of ensuring the accuracy of the results in the crash tests simulations. Body supports provide a link between the body and the car frame, and this has a critical effect on the impact test results of the car. The article discusses various options for modeling the body mounting by the degree of simplification from the simplest model with a rigid connection between the body and the frame to the model that takes into account the non-linearity of the stiffness characteristics of the supports, contact interaction between parts of the mounting and its surrounding parts, tension of the supports and failure. The results of virtual tests of a car with various options for modeling mountings were compared with the results of real tests. As a result of the study, a methodology for modeling the body supports was developed, which allows providing the necessary measurement error in virtual crash test modeling.

Practical examples of sheet metal forming simulations using the subroutine library ‘UMMDp’

With the common frame work of the user subroutine library, ‘UMMDp’, various constitutive models for metals have been implemented in several major commercial finite element (FE) codes. The implementation has been achieved by the material modeling working group of a non-profit organization, the Japan Association for Nonlinear CAE (JANCAE). Herein, we report the results of the finite element analyses on a typical metal forming problem solved using UMMDp. Moreover, since 2017, the CAE modeling working group has been tasked to provide more practical learning for the material models as well as extensive simulation knowledge. These activities are presented in this paper.

Development of the Internal Tube Material Properties for a Self-Inflating Tire

In this study, the tube material for Self-Inflating Tire was synthesized. A few suitable materials for the tube material compounding process were identified through a literature review. Using the material properties of this tube, CAE modeling was done for analysis. The ANSYS Fluid Structure Interaction (FSI) method was then used to consider the internal flow with the structure. In addition, a machine was prepared for testing the performance of the tube. The results of the CAE analysis were compared with results of the testing machine. The developed equipment and systems can be used for the manufacture of high-performance and safe tires. Finally, the prototype of the tube was prepared and fitted in a tire, and the driving performance of the vehicle tested. Using this test result, compatibility of the tube's material has been confirmed.

Acoustic performance of industrial mufflers with CAE modeling and simulation

ABSTRACT This paper investigates the noise transmission performance of industrial mufflers widely used in ships based on the CAE modeling and simulation. Since the industrial mufflers have very complicated internal structures, the conventional Transfer Matrix Method (TMM) is of limited use. The CAE modeling and simulation is therefore required to incorporate commercial softwares: CATIA for geometry modeling, MSC/PATRAN for FE meshing and LMS/SYSNOISE for analysis. Main sources of difficulties in this study are led by complicated arrangement of reactive ele- ments, perforated walls and absorption materials. The reactive elements and absorbent materials are modeled by applying boundary conditions given by impedance. The perforated walls are modeled by applying the transfer impedance on the duplicated node mesh. The CAE approach presented in this paper is verified by comparing with the theoretical solution of a concentric-tube resonator and is applied for industrial mufflers.

W304 ボルト・ナット締結体のCAEモデリング手法の確立と産学共同研究の事例紹介

W304 ボルト・ナット締結体のCAEモデリング手法の確立と産学共同研究の事例紹介

A Feature-Based CAD-CAE Integrated Approach of Machine Tool and its Implementation

An analysis feature-based CAD-CAE integrated approach was proposed to solve the problems of rapidly CAE modeling for static and dynamic analysis process of machine tool. Firstly, analysis features were defined in CAD system and analysis feature library was constructed for machine tool and its structural components. Secondly, analysis feature model was constructed by attaching analysis feature to CAD model interactively. Finally, ANSYS parametric design language (APDL) file was generated automatically by mapping analysis features to APDL codes, which realized the integration of CAD system and ANSYS system. Based on application programming interface (API) of SolidWorks, a parametric CAD-CAE tool oriented to static and dynamic analysis of machine tool was developed, which realized parametric modeling and automatic analysis of machine tool and improved design efficiency and quality of machine tool.

A Kind of CAD/CAE Integrated Modeling Technology Based on FEATURE

A kind of CAD/CAE integrated modeling method based on feature is proposed. Firstly, analysis features are attached to CAD model of part and standard part library is formed. Secondly, the CAD model is created using standard parts. Thirdly, geometry information of analysis features is extracted from CAD model and is reconstructed automatically under CAE environment. Finally, based on feature-based meshing and combination technique, CAE model is built quickly. A prototype software for large-scale antenna structure (LSAS) CAD/CAE integrated modeling has been developed and used in performance analysis of a 16-meter-diameter LSAS. The method has been proved to be useful for improving speed, accuracy and consistency of complicated structure CAE modeling notably.

비 결정론적 최적화 기법을 이용한 선박의 CAE 모델링 자동화를 위한 지능형 에이전트 시스템의 개발

Recently, Korean shipbuilding industry is keeping up the position of world wide No. 1 in world shipbuildingmarket share. It is caused by endless efforts to develope new technologies and methods and fastdevelopment of IT technologies in Korea, to raise up its productivities and efficiency in shipbuildingindustry with many kinds of optimizing methods including genetic algorithm or artificial life algorithm...etc. In this paper, we have suggested the artificial life algorithm with relay search micro genetic algorithm.and we have improved a defect of simple genetic algorithm for its slow convergence speed and added avariety of solution candidates with applying relay search simple genetic algorithm. Finally, we havedeveloped intelligent agent system for ship CAE modeling. We have tried to offer some conveniences a shipengineer for repeated ship CAE modeling by changing ship design repeatedly and to increase its accuracy ofa ship model with it. Key words : Relay search micro genetic algorithm, Artificial life algorithm, Intelligent agent system