DEFORMTM 3D Research Articles

Study of Forging Forming of 7075 Aluminum Alloy Bicycle Pedal

Forging is simple and inexpensive in mass production. Metallic materials are processed through plastic deformation. This not only changes the appearance but also changes the internal organization of materials that improve mechanical properties. However, regarding manufacturing of plastic products, many processing factors must be controlled to obtain the required plastic strain and desired tolerance values. In this paper, we employed rigid-plastic finite element (FE) DEFORMTM software to investigate the plastic deformation behavior of an aluminum alloy (A7075) workpiece as it used to forge bicycle pedals. First we use Solid works 2010 3D graphics software to design the bicycle pedal of the mold and appearance, moreover import finite element (FE) DEFORMTM 3D software for analysis. The paper used rigid-plastic model analytical methods, and assuming mode to be rigid body. A series of simulation analyses in which the variables depend on different temperatures of the forging billet, round radius size of ram, punch speed, and mold temperature were revealed to confirm the predicted aluminum grain structure, effective stress, effective strain, and die radial load distribution for forging a bicycle pedal. The analysis results can provide references for forming bicycle pedal molds. Finally, this study identified the finite element results for high-strength design suitability of a 7075 aluminum alloy bicycle pedal.

A Study on the Cellphone Cover-Forming Process of Titanium Alloys Using the Finite Element Method

In recent years, the style of 3C products demanded thin and small results due to gradual trends, though most of the industry is forming a continuous manner of stamping. However, the material thickness cannot be changed in products. This paper employs the rigid-plastic finite element (FE) DEFORMTM 3D software to investigate the plastic deformation behavior of titanium alloy (Ti-6Al-4V) workpiece for the forming processes of cellphone covers. In addition, this study utilizes the Solid Work 2010 3D graphics-rendering software for modeling, which is simulation software used to import various forming process conditions. The software analyzes the effective strain, the effective stress, critical damage value, and the die radius load distribution of the work-piece. Furthermore, this study used simulative software to analyze its forming processes for changes in grain size of the microstructure. The analytical results confirm the suitability of the current finite element software for forming processes of cellphone covers.

Finite Element Analysis and Die Design of Extrusion Processes of Radial-Finned Heat Sink

There are many different types of manufacturing methods for heat sink fins in the current market. The aim of this study is to design an extrusion die for a radial-finned heat sink using a commercial finite element package, DEFORMTM 3D. We then conduct a series of simulation analyses with different variables such as friction factor, ram velocity, and fin gate stage of the die to evaluate the methods of decreasing the warping in the extrusion process. The die is assumed as a rigid body in the analyses. The results confirm the suitability of DEFORMTM 3D to design an extrusion die achieving a lower warping behavior of the radial-finned heat sink.

Rigid-Plastic Finite Element Analysis of Cross Wedge Rolling

In the cross wedge rolling process, many factors must be controlled to obtain the required plastic strain and desired tolerance values. The major factors include the wedge relative velocity, the forming angle, the spreading angle, and sectional reduction. This paper uses rigid-plastic finite element (FE) DEFORMTM 3D software to investigate the plastic deformation behavior of an aluminum alloy (A7075) workpiece as it is processed for cross wedge rolling. This study analyzes the effective strain, the effective stress, and the X-axial load distribution of the workpiece under various rolling conditions. Furthermore, using simulation software to analyze the changes to the microstructure by the rolling process, this study presents analytical results that confirm the suitability of the current finite element software for cross wedge rolling.

Finite Element Simulations of A1100 / A3003 (A6063) Sandwich Sheet Rolling Processing

This study performs DEFORMTM 3D three-dimensional finite element simulations to analyze the plastic deformation of A1100 / A3003 sandwich sheets during rolling. The finite element code is based on a rigid-plastic model, and the simulations in this study assume that the rollers are rigid bodies and that the deformation-induced change in temperature during rolling is negligible. The rolled product comprises a central sheet of A1100 aluminum alloy sandwiched between upper and lower sheets of either A3003 or A6063 aluminum alloy. The simulations examine the effects of sheet thickness and reduction ratio on the maximum effective stress, maximum effective strain, Y-direction load, and maximum damage induced within the rolled product. This study also compares the simulation results for the final thicknesses of the three layers in the rolled A1100 / A3003 (A6063) sandwich sheet with experimental measurements and bonding conditions.

Finite element modeling and three-dimensional simulation of the turning process incorporating the material hardness

Newly developed functionally graded workpieces made of AISI 6150 (51CrV4), pose great challenges to the machining process due to the combination of different material properties (e.g., hardness) within one workpiece. A material model including more information than experimentally identified stress-strain curves for different temperatures is necessary to model the process more realistically. Therefore, the Johnson-Cook material model has been implemented for three-dimensional turning simulations within the Finite Element software DEFORMTM 3D. This paper outlines the adopted method to modify the parameters of the Johnson-Cook material model for two-dimensional and three-dimensional FE-simulations in order to take material hardness into account. The primary objective was to improve passive and feed force computation by using this modeling approach, as it was observed that common material modeling showed large deviations of the feed force and passive force from the measured force components. The calculated feed force and passive force, as well as the cutting force, are validated experimentally. In conclusion it is shown that the application of the Johnson-Cook material model reveals more valid results for modeling the turning of workpieces with varying hardness values.

Finite element analysis of superplastic blow-forming of Ti-6Al-4V sheet into closed ellip-cylindrical die

Utilizing commercial DEFORM TM 3D finite element (FE) software, this study performs a series of numerical simulations to investigate the superplastic blow-forming of Ti-6Al-4V titanium alloy into a closed ellip-cylindrical die. In performing the simulations, it is assumed that the die is a rigid body and the titanium alloy sheet is a rigid-plastic material with homogeneous and isotropic properties. The simulations focus specifically on the respective effects of the shear friction factor, the die entry radius, the die height and the die’s short-axis length on the thickness, effective stress, effective strain and critical damage distributions within the blow-formed product. Overall, the simulation results confirm the suitability of the DEFORM TM 3D software for modelling the superplastic blow-forming of Ti-6Al-4V titanium alloy.

Die structure optimization of equal channel angular extrusion for AZ31 magnesium alloy based on finite element method

Three-dimensional(3D) geometric models with different corner angles (90° and 120°) and with or without inner round fillets in the bottom die were designed. Some important process parameters were regarded as the calculation conditions used in DEFORM TM-3D software, such as stress—strain data of compression test for AZ31 magnesium, temperatures of die and billet, and friction coefficient. Influence of friction coefficient on deformation process was discussed. The results show that reasonable lubrication condition is important to plastic deformation. The change characteristics for distributions of effective stress and strain during an equal channel angular extrusion (ECAE) process with inner angle of 90° and without fillets at outer corner were described. Inhomogeneity index ( C) was defined and deformation heterogeneity of ECAE was analyzed from the simulation and experiment results. The deformation homogeneity caused by fillets at outer corner increased compared with the die without fillets. The cumulated maximum strains decrease with increasing the fillets of outer corner in ECAE die and the inner corner angle. The analysis results show that better structures of ECAE die including appropriate outer corner fillet and the inner corner angle of 90° for the die can improve the strain and ensure plastic deformation homogenization to a certain extent. The required extrusion force drops with increasing the fillet made at outer corner in ECAE die. It is demonstrated that the prediction results are in good agreement with experiments and the theoretical calculation and the research conclusions in literatures.

OTIMIZAÇÃO DO PERFIL DE VELOCIDADE DE UMA PRENSA HIDRÁULICA DE FORJAMENTO ATRAVÉS DE SIMULAÇÃO POR ELEMENTOS FINITOS

A hydraulic press to forging steel ingots contains parts and components that are much requested. In order to limit the efforts in these parts and components, and also to decrease maintenance, it is studied ways to optimize parameters of hydraulic press speed in function of maximum load available. In this optimization study, finite element simulations using commercial software called DEFORM TM 3D are performed. These simulations are carried out with different speed curves during upsetting process of AISI 4340 steel ingot assuring same deformation work between processes. Optimized speed is validated by real performed forging. It was achieved equivalent deforming work levels and the maximum load applied was decreased. Therefore, critical parts and components of hydraulic press were less requested.

Investigation into cold extrusion of aluminum billets using three-dimensional finite element method

Abstract This paper employs rigid-plastic finite element DEFORM™ 3D software to investigate the plastic deformation behavior of an aluminum billet during its axisymmetric extrusion through a conical die. The die and container are assumed to be rigid bodies and the temperature change induced during extrusion is ignored. Under various extrusion conditions, the present numerical analysis investigates the stress–strain distribution, the damage factor distributions, the die load and the flow velocity of the billet at the exit. The relative influences of the semi-angle of the die, the extrusion ratio and the friction factors are systematically examined. The simulation results confirm the suitability of the current finite element software for modeling the three-dimensional cold extrusion of aluminum billets.

Use of Taguchi method to study a robust design for the sectioned beams curvature during rolling

Abstract Finite element DEFORM™ 3D software is employed to examine the plastic deformation behavior of V-sectioned and T-sectioned porous beams at the roll gap under various rolling conditions. The finite element code is based on a rigid–plastic model in which it is assumed that the rolls are rigid bodies and that the temperature change induced in the beams during rolling is sufficiently small that it can be ignored. The analytical model is used to systematically examine the effect of the inclination angle of the roll profile, the friction factors between the rolls and the beam, the roll radii and the angular speed of the upper and lower rolls on the curvature of the rolled beam, the rolling torque, the effective strain, the effective stress and the variation of density of the rolled product at the exit. The Taguchi method is employed to design the rolling parameters to optimize the curvature of the beams. The analytic results have shown that: (1) the inclination angle of the inner part (i.e. vacancy) of the upper roll, the friction factor of the lower roll, the angular velocity of the lower roll and the roll radii, respectively, all have a significant influence upon the curvature of the rolled V-sectioned product, κ = 1/ra; (2) the reduction ratio of the porous beam, the friction factor of the lower roll, the angular velocity of the lower roll, and the roll radii, respectively, all have a significant influence upon the curvature of the rolled T-sectioned product, κ = 1/ra.

Isothermal forging modelling of 2618 + 20% Al 2O 3p metal matrix composite

The isothermal forging of 2618 + 20% Al 2O 3p metal matrix composite has been studied by employing hot compression tests in the temperature and strain rate ranges of 450–500 °C and 10 −2–10 −1 s −1, respectively. The flow stress curves of the material in all test conditions were used to model the forging of an aerospace component by DEFORM™ 3D code in order to identify the best forging conditions. After simulations, the component was isothermally forged and the resulting microstructure was observed by using optical microscopy in order to study the modifications acting during deformation.