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.
Abstract: Springback is a significant problem in the sheet metal
forming process. When the tools are released after the stage of
forming, the product springs out, because of the action of the internal
stresses. In many cases the deviation of form is too large and the
compensation of the springback is necessary. The precise prediction
of the springback of product is increasingly significant for the design
of the tools and for compensation because of the higher ratio of the
yield stress to the elastic modulus.
The main object in this paper was to study the effect of the
anisotropy on the springback for three directions of rolling: 0°, 45°
and 90°. At the same time, we highlighted the influence of three
different metallic materials: Aluminum, Steel and Galvanized steel.
The original of our purpose consist on tests which are ensured by
adapting a U-type stretching-bending device on a tensile testing
machine, where we studied and quantified the variation of the
springback according to the direction of rolling. We also showed the
role of lubrication in the reduction of the springback.
Moreover, in this work, we have studied important characteristics
in deep drawing process which is a springback. We have presented
defaults that are showed in this process and many parameters
influenced a springback.
Finally, our results works lead us to understand the influence of
grains orientation with different metallic materials on the springback
and drawing some conclusions how to concept deep drawing tools. In
addition, the conducted work represents a fundamental contribution
in the discussion the industry application.
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.
Abstract: The tubes in an Ammonia primary reformer furnace
operate close to the limits of materials technology in terms of the
stress induced as a result of very high temperatures, combined with
large differential pressures across the tube wall. Operation at tube
wall temperatures significantly above design can result in a rapid
increase in the number of tube failures, since tube life is very
sensitive to the absolute operating temperature of the tube. Clearly it
is important to measure tube wall temperatures accurately in order to
prevent premature tube failure by overheating.. In the present study,
the catalyst tubes in an Ammonia primary reformer has been modeled
taking into consideration heat, mass and momentum transfer as well
as reformer characteristics.. The investigations concern the effects of
tube characteristics and superficial tube wall temperatures on of the
percentage of heat flux, unconverted methane and production of
Hydrogen for various values of steam to carbon ratios. The results
show the impact of catalyst tubes length and diameters on the
performance of operating parameters in ammonia primary reformers.
Abstract: During the last few years, several sheet hydroforming
processes have been introduced. Despite the advantages of these
methods, they have some limitations. Of the processes, the two main
ones are the standard hydroforming and hydromechanical deep
drawing. A new sheet hydroforming die set was proposed that has the
advantages of both processes and eliminates their limitations. In this
method, a polyurethane plate was used as a part of the die-set to
control the blank holder force. This paper outlines the Taguchi
optimization methodology, which is applied to optimize the effective
parameters in forming cylindrical cups by the new die set of sheet
hydroforming process. The process parameters evaluated in this
research are polyurethane hardness, polyurethane thickness, forming
pressure path and polyurethane hole diameter. The design of
experiments based upon L9 orthogonal arrays by Taguchi was used
and analysis of variance (ANOVA) was employed to analyze the
effect of these parameters on the forming pressure. The analysis of
the results showed that the optimal combination for low forming
pressure is harder polyurethane, bigger diameter of polyurethane hole
and thinner polyurethane. Finally, the confirmation test was derived
based on the optimal combination of parameters and it was shown
that the Taguchi method is suitable to examine the optimization
process.
Abstract: Today, Hydroforming technology provides an
attractive alternative to conventional matched die forming, especially
for cost-sensitive, lower volume production, and for parts with
irregular contours. In this study the critical fluid pressures which lead
to rupture in the workpiece has been investigated by theoretical and
finite element methods. The axisymmetric analysis was developed to
investigate the tearing phenomenon in cylindrical Hydroforming
Deep Drawing (HDD). By use of obtained equations the effect of
anisotropy, drawing ratio, sheet thickness and strain hardening
exponent on tearing diagram were investigated.
Abstract: The plastic forming process of sheet plate takes an
important place in forming metals. The traditional techniques of tool
design for sheet forming operations used in industry are experimental
and expensive methods. Prediction of the forming results,
determination of the punching force, blank holder forces and the
thickness distribution of the sheet metal will decrease the production
cost and time of the material to be formed. In this paper, multi-stage
deep drawing simulation of an Industrial Part has been presented
with finite element method. The entire production steps with
additional operations such as intermediate annealing and springback
has been simulated by ABAQUS software under axisymmetric
conditions. The simulation results such as sheet thickness
distribution, Punch force and residual stresses have been extracted in
any stages and sheet thickness distribution was compared with
experimental results. It was found through comparison of results, the
FE model have proven to be in close agreement with those of
experiment.
Abstract: In a metal forming process, the friction between the
material and the tools influences the process by modifying the stress
distribution of the workpiece. This frictional behaviour is often taken
into account by using a constant coefficient of friction in the finite
element simulations of sheet metal forming processes. However,
friction coefficient varies in time and space with many parameters.
The Stribeck friction model is investigated in this study to predict
springback behaviour of AA6061-T4 sheets during V-bending
process. The coefficient of friction in Stribeck curve depends on
sliding velocity and contact pressure. The plane-strain bending
process is simulated in ABAQUS/Standard. We compared the
computed punch load-stroke curves and springback related to the
constant coefficient of friction with the defined friction model. The
results clearly showed that the new friction model provides better
agreement between experiments and results of numerical simulations.
The influence of friction models on stress distribution in the
workpiece is also studied numerically
Abstract: To investigates the effect of fiberglass clamping
process improvement on drape simulation prediction. This has
great effect on the mould and the fiber during manufacturing
process. This also, improves the fiber strain, the quality of the
fiber orientation in the area of folding and wrinkles formation
during the press-forming process. Drape simulation software
tool was used to digitalize the process, noting the formation
problems on the contour sensitive part. This was compared
with the real life clamping processes using single and double
frame set-ups to observe the effects. Also, restrains are
introduced by using clips, and the G-clamps with predetermine
revolution to; restrain the fabric deformation during the
forming process.The incorporation of clamping and fabric
restrain deformation improved on the prediction of the
simulation tool. Therefore, for effective forming process,
incorporation of clamping process into the drape simulation
process will assist in the development of fiberglass application
in manufacturing process.
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.
Abstract: The running logs of a process hold valuable
information about its executed activity behavior and generated activity
logic structure. Theses informative logs can be extracted, analyzed and
utilized to improve the efficiencies of the process's execution and
conduction. One of the techniques used to accomplish the process
improvement is called as process mining. To mine similar processes is
such an improvement mission in process mining. Rather than directly
mining similar processes using a single comparing coefficient or a
complicate fitness function, this paper presents a simplified heuristic
process mining algorithm with two similarity comparisons that are
able to relatively conform the activity logic sequences (traces) of
mining processes with those of a normalized (regularized) one. The
relative process conformance is to find which of the mining processes
match the required activity sequences and relationships, further for
necessary and sufficient applications of the mined processes to process
improvements. One similarity presented is defined by the relationships
in terms of the number of similar activity sequences existing in
different processes; another similarity expresses the degree of the
similar (identical) activity sequences among the conforming processes.
Since these two similarities are with respect to certain typical behavior
(activity sequences) occurred in an entire process, the common
problems, such as the inappropriateness of an absolute comparison and
the incapability of an intrinsic information elicitation, which are often
appeared in other process conforming techniques, can be solved by the
relative process comparison presented in this paper. To demonstrate
the potentiality of the proposed algorithm, a numerical example is
illustrated.
Abstract: This research was conducted to develop a correlation
between microstructure of HSLA steel and the mechanical properties
that occur as a result of both laser and mechanical forming processes
of the metal. The technique of forming flat metals by applying laser
beams is a relatively new concept in the manufacturing industry.
However, the effects of laser energy on the stability of metal alloy
phases have not yet been elucidated in terms of phase
transformations and microhardness. In this work, CO2 laser source
was used to irradiate the surface of a flat metal then the
microstructure and microhardness of the metal were studied on the
formed specimen. The extent to which the microstructure changed
depended on the heat inputs of up to 1000 J/cm2 with cooling rates of
about 4.8E+02 K/s. Experimental results revealed that the irradiated
surface of a HSLA steel had transformed to austenitic structure
during the heating process.
Abstract: Gasoline Octane Number is the standard measure of
the anti-knock properties of a motor in platforming processes, that is
one of the important unit operations for oil refineries and can be
determined with online measurement or use CFR (Cooperative Fuel
Research) engines. Online measurements of the Octane number can
be done using direct octane number analyzers, that it is too
expensive, so we have to find feasible analyzer, like ANFIS
estimators.
ANFIS is the systems that neural network incorporated in fuzzy
systems, using data automatically by learning algorithms of NNs.
ANFIS constructs an input-output mapping based both on human
knowledge and on generated input-output data pairs.
In this research, 31 industrial data sets are used (21 data for training
and the rest of the data used for generalization). Results show that,
according to this simulation, hybrid method training algorithm in
ANFIS has good agreements between industrial data and simulated
results.
Abstract: In this study, a reformer model simulation to use
refinery (Farashband refinery, Iran) waste natural gas. In the
petroleum and allied sectors where natural gas is being encountered
(in form of associated gas) without prior preparation for its positive
use, its combustion (which takes place in flares, an equipment through
which they are being disposed) has become a great problem because
of its associated environmental problems in form of gaseous emission.
The proposed model is used to product syngas from waste natural gas.
A detailed steady model described by a set of ordinary differential and
algebraic equations was developed to predict the behavior of the
overall process. The proposed steady reactor model was validated
against process data of a reformer synthesis plant recorded and a good
agreement was achieved. H2/CO ratio has important effect on Fischer-
Tropsch synthesis reactor product and we try to achieve this parameter
with best designing reformer reactor. We study different kind of
reformer reactors and then select auto thermal reforming process of
natural gas in a fixed bed reformer that adjustment H2/CO ratio with
CO2 and H2O injection. Finally a strategy was proposed for prevention
of extra natural gas to atmosphere.
Abstract: Air bending is one of the important metal forming
processes, because of its simplicity and large field application.
Accuracy of analytical and empirical models reported for the analysis
of bending processes is governed by simplifying assumption and do
not consider the effect of dynamic parameters. Number of researches
is reported on the finite element analysis (FEA) of V-bending, Ubending,
and air V-bending processes. FEA of bending is found to be
very sensitive to many physical and numerical parameters. FE
models must be computationally efficient for practical use. Reported
work shows the 3D FEA of air bending process using Hyperform LSDYNA
and its comparison with, published 3D FEA results of air
bending in Ansys LS-DYNA and experimental results. Observing the
planer symmetry and based on the assumption of plane strain
condition, air bending problem was modeled in 2D with symmetric
boundary condition in width. Stress-strain results of 2D FEA were
compared with 3D FEA results and experiments. Simplification of
air bending problem from 3D to 2D resulted into tremendous
reduction in the solution time with only marginal effect on stressstrain
results. FE model simplification by studying the problem
symmetry is more efficient and practical approach for solution of
more complex large dimensions slow forming processes.
Abstract: Future astronomical projects on large space x-ray
imaging telescopes require novel substrates and technologies for the
construction of their reflecting mirrors. The mirrors must be
lightweight and precisely shaped to achieve large collecting area with
high angular resolution. The new materials and technologies must be
cost-effective. Currently, the most promising materials are glass or
silicon foils. We focused on precise shaping these foils by thermal
forming process. We studied free and forced slumping in the
temperature region of hot plastic deformation and compared the
shapes obtained by the different slumping processes. We measured
the shapes and the surface quality of the foils. In the experiments, we
varied both heat-treatment temperature and time following our
experiment design. The obtained data and relations we can use for
modeling and optimizing the thermal forming procedure.
Abstract: The forming process parameters of Selective Laser
Sintering(SLS) directly affect the forming efficiency and forming
quality. Therefore, to determine reasonable process parameters is
particularly important. In this paper, the weight of each target of the
forming quality and efficiency is firstly calculated with the Analytic
Hierarchy Process. And then the size of each target is measured by
orthogonal experiment. Finally, the sum of the product of each target
with the weight is compared to the process parameters in each group
and obtained the optimal molding process parameters.
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.
Abstract: The fundamental defect inherent to the thermoforming
technology is wall-thickness variation of the products due to
inadequate thermal processing during production of polymer. A
nonlinear viscoelastic rheological model is implemented for
developing the process model. This model describes deformation
process of a sheet in thermoforming process. Because of relaxation
pause after plug-assist stage and also implementation of two stage
thermoforming process have minor wall-thickness variation and
consequently better mechanical properties of polymeric articles. For
model validation, a comparative analysis of the theoretical and
experimental data is presented.