3D free bending process,an advanced metal forming technology,has attracted much attention due to its unique geometrical flexibility and efficiency.Filling tubes with materials may effectively reduce the distortion in ...3D free bending process,an advanced metal forming technology,has attracted much attention due to its unique geometrical flexibility and efficiency.Filling tubes with materials may effectively reduce the distortion in the cross-section area and restrain wrinkling and collapse of tube wall.In the present study,the impacts of filling different materials on the copper tubes during 3D free bending process were investigated.We have found that copper tubes filled with low melting point alloys could induce the most uniform stress distribution,which result in better formability and moderate thickness changing rates when compared to SS304 steel balls and PU rubbers.The lowest ellipticity reached to 1.467%.展开更多
In meandering rivers, the flow pattern is highly complex, with specific characteristics at bends that are not observed along straight paths. A numerical model can be effectively used to predict such flow fields. Since...In meandering rivers, the flow pattern is highly complex, with specific characteristics at bends that are not observed along straight paths. A numerical model can be effectively used to predict such flow fields. Since river bends are not uniform-some are divergent and others convergent-in this study, after the SSIIM 3-D model was calibrated using the result of measurements along a uniform 180° bend with a width of 0.6 m, a similar but convergent 180v bend, 0.6 m to 0.45 m wide, was simulated using the SSI1M 3-D numerical model. Flow characteristics of the convergent 180° bend, including lengthwise and vertical velocity profiles, primary and secondary flows, lengthwise and widtbwise slopes of the water surface, and the helical flow strength, were compared with those of the uniform 180° bend. The verification results of the model show that the numerical model can effectively simulate the flow field in the uniform bend. In addition, this research indicates that, in a convergent channel, the maximum velocity path at a plane near the water surface crosses the channel＇s centerline at about a 30° to 40° cross-section, while in the uniform bend, this occurs at about the 50° cross-section. The varying range of the water surface elevation is wider in the convergent channel than in the uniform one, and the strength of the helical flow is generally greater in the uniform channel than in the convergent one. Also, unlike the uniform bend, the convergent bend exhibits no rotational cell against the main direction of secondary flow rotation at the 135° cross-section.展开更多
Repeated bending occurs toward the direction of rail head and rail base during the cooling which can lead to significant bending deformation and residual stress after cooling.The longer the rail is,the more obvious th...Repeated bending occurs toward the direction of rail head and rail base during the cooling which can lead to significant bending deformation and residual stress after cooling.The longer the rail is,the more obvious this phenomenon is.In addition to cooling function,a kind of cooling bed with a pre-bending process is used in order to solve this problem on 100 m rail.The synchronous movements on this cooling bed can be realized by the automatic control system after establishing the mathematical model of bending deformation after rolling.The rail is reversely bent toward the rail base before cooling according to the pre-bending control of the pre-bending curve and is straight after cooling,which can realize the control of the residual stress after pre-bending and straightening.The straightening residual stress is significantly reduced after the pre-bending.展开更多
In this study,FLUENT software was employed to simulate the flow pattern and water depth changes in a 120° sharp bend at four discharge rates.To verify the numerical model,a 90° sharp bend was first modeled w...In this study,FLUENT software was employed to simulate the flow pattern and water depth changes in a 120° sharp bend at four discharge rates.To verify the numerical model,a 90° sharp bend was first modeled with a three-dimensional numerical model,and the results were compared with available experimental results.Based on the numerical model validation,a 120° bend was simulated.The results show that the rate of increase of the water depth at the cross-section located 40 cm before the bend,compared with the cross-sections located 40 cm and 80 cm after the bend,decreases with the increase of the normal water depth in the 120° curved channel.Moreover,with increasing normal water depth,the dimensionless water depth change decreases at all cross-sections.At the interior cross-sections of the bend,the transverse water depth slope of the inner half-width is always greater than that of the outer half-width of the channel.Hence,the water depth slope is nonlinear at each crosssection in sharp bends.Two equations reflecting the relationships between the maximum and minimum dimensionless water depths and the normal water depth throughout the channel were obtained.展开更多
An original plastic equivalent model was proposed to solve the problem of excessive FEM simulation time when designing the press bend forming path and optimizing the process parameters of press bend forming of the int...An original plastic equivalent model was proposed to solve the problem of excessive FEM simulation time when designing the press bend forming path and optimizing the process parameters of press bend forming of the integrally stiffened aircraft panels. Based on the in-depth analysis of the mechanics of the bending and springback of the detailed model and the equivalent model of the integral panels,the plastic equivalent model of the virtual material with special initial yield stress and hardening coefficients was constructed. FEM results indicate that the objective of getting the similar contour with the same press bend forming path is achieved with the error less than 6%,and the efficiency of FEM simulation is improved by more than 80%. The plastic equivalent model is valuable and essential for the further research on the press bend forming process of large scale complicated integral panels.展开更多
The upper reach of the Yellow River from Daliushu to Shapotou consists of five bends and has complex topography. A two-dimensional Re-Normalisation Group （RNG） k-ε model was developed to simulate the flow in the re...The upper reach of the Yellow River from Daliushu to Shapotou consists of five bends and has complex topography. A two-dimensional Re-Normalisation Group （RNG） k-ε model was developed to simulate the flow in the reach. In order to take the circulation currents in the bends into account, the momentum equations were improved by adding an additional source term. Comparison of the numerical simulation with field measurements indicates that the improved two-dimensional depth-averaged RNG k-e model can improve the accuracy of the numerical simulation. A rapid adaptive algorithm was constructed, which can automatically adjust Manning＇s roughness coefficient in different parts of the study river reach. As a result, not only can the trial computation time be significantly shortened, but the accuracy of the numerical simulation can also be greatly improved. Comparison of the simulated and measured water surface slopes for four typical cases shows that the longitudinal and transverse slopes of the water surface increase with the average velocity upstream. In addition, comparison was made between the positions of the talweg and the main streamline, which coincide for most of the study river reach. However, deviations between the positions of the talweg and the main streamline were found at the junction of two bends, at the position where the river width suddenly decreases or increases.展开更多
To study the bending deformation of the lithosphere, the simplification of replacing a spherical shell by a plate model is usually made. Based on the differential equations for the bending of plates and shallow spheri...To study the bending deformation of the lithosphere, the simplification of replacing a spherical shell by a plate model is usually made. Based on the differential equations for the bending of plates and shallow spherical shells, an expression for the error caused by such a simplification is derived in this paper. The effect of model sizes on the error is discussed. It is proved that if we replace the shallow spherical shell by a plate model to solve the bending deformation of lithospheric plate, a large error will be caused. In contrast, if we use a plate on an elastic foundation instead, an approximate solution closer to that of spherical shell can be obtained. In such a way, the error can be reduced effectively and the actual geological condition can be modeled more closely.展开更多
In order to find out the optimal press bend forming path in fabricating aircraft integral panels, this article proposes a new method on the basis of the authors＇ previous work. It is composed of the finite element me...In order to find out the optimal press bend forming path in fabricating aircraft integral panels, this article proposes a new method on the basis of the authors＇ previous work. It is composed of the finite element method （FEM） equivalent model, the surface curvature analysis, the artificial neural network response surface and the genetic algorithm. The method begins with analyzing the objective＇s shape curvature to determine the bending position. Then it optimizes the punch travel at each bending position by the following steps： （1） Establish a multi-step press bend forming FEM equivalent model, with which the FEM ex- periments designed with the Taguchi method are performed. （2） Construct a back-propagation （BP） neural network response surface with the data from the FEM experiments. （3） Use the genetic algorithm to optimize the neural network response surface as the objective function. Finally, this method is verified by press bending a complicated double-curvature grid-type stiffened panel and bears out its effectiveness and intrinsic worth in designing the press bend forming path.展开更多
Tube thinning control without wrinkling occurring is a key problem urgently to be solved for improving the forming qualities in numerical control （NC） bending processes of large-diameter Al-alloy thin-walled tubes ...Tube thinning control without wrinkling occurring is a key problem urgently to be solved for improving the forming qualities in numerical control （NC） bending processes of large-diameter Al-alloy thin-walled tubes （AATTs）. It may be a way solving this problem to exert axial compression loads （ACL） on the tube end in the bending. Thus, this article establishes a three-dimensional （3D） elastic-plastic explicit finite element （FE） model for the bending under ACL and has its reliability verified. Through a multi-index orthogonal experiment design, a combination of process parameters, each expressed by a proper range, for this FE model is derived to overcome the compression instability on tube ends. By combining the FE model with a wrinkling energy prediction model, an in-depth study is conducted on the forming characteristics of large-diameter AATTs with small bending radii and it can be concluded that （1） The larger the tube diameters and the smaller the bending radii, the larger the induced tangent tension stress zones on tube intrados, by which the tube maximum tangent compression stress zones will be partitioned in the bending processes; thus, the smaller the ACL roles in decreasing thinning degrees and the larger the compression instability possibilities on tube ends. （2） The tube wrinkling possibilities under ACL are larger than without ACL acting in the earlier forming periods, and smaller in the later ones. （3） For the tubes with a size factor less than 80, the ACL roles in decreasing thinning degrees are stronger than in increasing wrinkling possibilities.展开更多
基金financial support from the Open Research Funds of the Jiangsu Key Laboratory of Nuclear Energy Equipment Materials Engineering of China(No.NJ20170012)the China Aviation Science Foundation(No.2016ZE52047)the Jiangsu Province Science and Technology Program of China(No.BE2016156).
文摘3D free bending process,an advanced metal forming technology,has attracted much attention due to its unique geometrical flexibility and efficiency.Filling tubes with materials may effectively reduce the distortion in the cross-section area and restrain wrinkling and collapse of tube wall.In the present study,the impacts of filling different materials on the copper tubes during 3D free bending process were investigated.We have found that copper tubes filled with low melting point alloys could induce the most uniform stress distribution,which result in better formability and moderate thickness changing rates when compared to SS304 steel balls and PU rubbers.The lowest ellipticity reached to 1.467%.
文摘In meandering rivers, the flow pattern is highly complex, with specific characteristics at bends that are not observed along straight paths. A numerical model can be effectively used to predict such flow fields. Since river bends are not uniform-some are divergent and others convergent-in this study, after the SSIIM 3-D model was calibrated using the result of measurements along a uniform 180° bend with a width of 0.6 m, a similar but convergent 180v bend, 0.6 m to 0.45 m wide, was simulated using the SSI1M 3-D numerical model. Flow characteristics of the convergent 180° bend, including lengthwise and vertical velocity profiles, primary and secondary flows, lengthwise and widtbwise slopes of the water surface, and the helical flow strength, were compared with those of the uniform 180° bend. The verification results of the model show that the numerical model can effectively simulate the flow field in the uniform bend. In addition, this research indicates that, in a convergent channel, the maximum velocity path at a plane near the water surface crosses the channel＇s centerline at about a 30° to 40° cross-section, while in the uniform bend, this occurs at about the 50° cross-section. The varying range of the water surface elevation is wider in the convergent channel than in the uniform one, and the strength of the helical flow is generally greater in the uniform channel than in the convergent one. Also, unlike the uniform bend, the convergent bend exhibits no rotational cell against the main direction of secondary flow rotation at the 135° cross-section.
基金the National Natural Science Foundation of China (No.50765004)
文摘Repeated bending occurs toward the direction of rail head and rail base during the cooling which can lead to significant bending deformation and residual stress after cooling.The longer the rail is,the more obvious this phenomenon is.In addition to cooling function,a kind of cooling bed with a pre-bending process is used in order to solve this problem on 100 m rail.The synchronous movements on this cooling bed can be realized by the automatic control system after establishing the mathematical model of bending deformation after rolling.The rail is reversely bent toward the rail base before cooling according to the pre-bending control of the pre-bending curve and is straight after cooling,which can realize the control of the residual stress after pre-bending and straightening.The straightening residual stress is significantly reduced after the pre-bending.
文摘In this study,FLUENT software was employed to simulate the flow pattern and water depth changes in a 120° sharp bend at four discharge rates.To verify the numerical model,a 90° sharp bend was first modeled with a three-dimensional numerical model,and the results were compared with available experimental results.Based on the numerical model validation,a 120° bend was simulated.The results show that the rate of increase of the water depth at the cross-section located 40 cm before the bend,compared with the cross-sections located 40 cm and 80 cm after the bend,decreases with the increase of the normal water depth in the 120° curved channel.Moreover,with increasing normal water depth,the dimensionless water depth change decreases at all cross-sections.At the interior cross-sections of the bend,the transverse water depth slope of the inner half-width is always greater than that of the outer half-width of the channel.Hence,the water depth slope is nonlinear at each crosssection in sharp bends.Two equations reflecting the relationships between the maximum and minimum dimensionless water depths and the normal water depth throughout the channel were obtained.
基金Project(50675010) supported by the National Natural Science Foundation of China
文摘An original plastic equivalent model was proposed to solve the problem of excessive FEM simulation time when designing the press bend forming path and optimizing the process parameters of press bend forming of the integrally stiffened aircraft panels. Based on the in-depth analysis of the mechanics of the bending and springback of the detailed model and the equivalent model of the integral panels,the plastic equivalent model of the virtual material with special initial yield stress and hardening coefficients was constructed. FEM results indicate that the objective of getting the similar contour with the same press bend forming path is achieved with the error less than 6%,and the efficiency of FEM simulation is improved by more than 80%. The plastic equivalent model is valuable and essential for the further research on the press bend forming process of large scale complicated integral panels.
基金supported by the National Natural Science Foundation of China(Grants No.11361002 and 91230111)the Natural Science Foundation of Ningxia,China(Grant No.NZ13086)+1 种基金the Project of Beifang University of Nationalities,China(Grant No.2012XZK05)the Foreign Expert Project of Beifang University of Nationalities,China,and the Visiting Scholar Foundation of State Key Laboratory of Water Resources and Hydropower Engineering Science,Wuhan University,China(Grant No.2013A011)
文摘The upper reach of the Yellow River from Daliushu to Shapotou consists of five bends and has complex topography. A two-dimensional Re-Normalisation Group （RNG） k-ε model was developed to simulate the flow in the reach. In order to take the circulation currents in the bends into account, the momentum equations were improved by adding an additional source term. Comparison of the numerical simulation with field measurements indicates that the improved two-dimensional depth-averaged RNG k-e model can improve the accuracy of the numerical simulation. A rapid adaptive algorithm was constructed, which can automatically adjust Manning＇s roughness coefficient in different parts of the study river reach. As a result, not only can the trial computation time be significantly shortened, but the accuracy of the numerical simulation can also be greatly improved. Comparison of the simulated and measured water surface slopes for four typical cases shows that the longitudinal and transverse slopes of the water surface increase with the average velocity upstream. In addition, comparison was made between the positions of the talweg and the main streamline, which coincide for most of the study river reach. However, deviations between the positions of the talweg and the main streamline were found at the junction of two bends, at the position where the river width suddenly decreases or increases.
文摘To study the bending deformation of the lithosphere, the simplification of replacing a spherical shell by a plate model is usually made. Based on the differential equations for the bending of plates and shallow spherical shells, an expression for the error caused by such a simplification is derived in this paper. The effect of model sizes on the error is discussed. It is proved that if we replace the shallow spherical shell by a plate model to solve the bending deformation of lithospheric plate, a large error will be caused. In contrast, if we use a plate on an elastic foundation instead, an approximate solution closer to that of spherical shell can be obtained. In such a way, the error can be reduced effectively and the actual geological condition can be modeled more closely.
基金Specialized Research Fund for the Doctoral Program of High Education of China (20091102110021)
文摘In order to find out the optimal press bend forming path in fabricating aircraft integral panels, this article proposes a new method on the basis of the authors＇ previous work. It is composed of the finite element method （FEM） equivalent model, the surface curvature analysis, the artificial neural network response surface and the genetic algorithm. The method begins with analyzing the objective＇s shape curvature to determine the bending position. Then it optimizes the punch travel at each bending position by the following steps： （1） Establish a multi-step press bend forming FEM equivalent model, with which the FEM ex- periments designed with the Taguchi method are performed. （2） Construct a back-propagation （BP） neural network response surface with the data from the FEM experiments. （3） Use the genetic algorithm to optimize the neural network response surface as the objective function. Finally, this method is verified by press bending a complicated double-curvature grid-type stiffened panel and bears out its effectiveness and intrinsic worth in designing the press bend forming path.
基金National Natural Science Foundation of China (59975076, 50175092)National Science Fund of China for Distinguished Young Scholars (50225518)
文摘Tube thinning control without wrinkling occurring is a key problem urgently to be solved for improving the forming qualities in numerical control （NC） bending processes of large-diameter Al-alloy thin-walled tubes （AATTs）. It may be a way solving this problem to exert axial compression loads （ACL） on the tube end in the bending. Thus, this article establishes a three-dimensional （3D） elastic-plastic explicit finite element （FE） model for the bending under ACL and has its reliability verified. Through a multi-index orthogonal experiment design, a combination of process parameters, each expressed by a proper range, for this FE model is derived to overcome the compression instability on tube ends. By combining the FE model with a wrinkling energy prediction model, an in-depth study is conducted on the forming characteristics of large-diameter AATTs with small bending radii and it can be concluded that （1） The larger the tube diameters and the smaller the bending radii, the larger the induced tangent tension stress zones on tube intrados, by which the tube maximum tangent compression stress zones will be partitioned in the bending processes; thus, the smaller the ACL roles in decreasing thinning degrees and the larger the compression instability possibilities on tube ends. （2） The tube wrinkling possibilities under ACL are larger than without ACL acting in the earlier forming periods, and smaller in the later ones. （3） For the tubes with a size factor less than 80, the ACL roles in decreasing thinning degrees are stronger than in increasing wrinkling possibilities.
