In three-dimensional free-bending forming(3D-FBF),the tube is not overly constrained,and the plastic deformation behavior and forming quality of the bent tube are significantly affected by the critical structure of th...In three-dimensional free-bending forming(3D-FBF),the tube is not overly constrained,and the plastic deformation behavior and forming quality of the bent tube are significantly affected by the critical structure of the forming die lining.However,the effects of die-lining structural parameters on the tube quality,and a method to determine the combination of die-lining structural parameters is yet to be devised.This study aims to propose a new framework that allows one to understand the effects of various die-lining structural parameters on tube quality and to propose the best combination of die-lining structural parameters.First,finite-element modeling is performed to simulate 3D-FBF and examine the effects of individual die-lining structures on the quality of tube formation.The simulation results show that the deformation-zone length and die gap are positively correlated with the tube-section distortion and wall-thickness variation,whereas it shows an opposite trend with respect to the bending radius.Additionally,the lining chamfer radius of the bending die and the guide lining chamfer radius minimally affect the tube forming quality.Subsequently,the optimal die-lining structure is obtained using the response-surface method.The tube cross-sectional distortion rate reduced from 2.73 to 2.53%after the die lining is optimized.Additionally,the average inner-wall thickness reduced to 1.06 mm,whereas the average outer-wall thickness increased to 0.97 mm.This paper proposes a method for optimizing the forming-die-lining mechanism and for improving the tube forming quality in 3D-FBF.展开更多
The contact problem of deformed rough surfaces exists widely in complex engineering structures.How to reveal the influence mechanism of surface deformation on the contact properties is a key issue in evaluating the in...The contact problem of deformed rough surfaces exists widely in complex engineering structures.How to reveal the influence mechanism of surface deformation on the contact properties is a key issue in evaluating the interface performances of the engineering structures.In this paper,a contact model is established,which is suitable for tensile and bending deformed contact surfaces.Four contact forms of asperities are proposed,and their distribution characteristics are analyzed.This model reveals the mechanism of friction generation from the perspective of the force balance of asperity.The results show the contact behaviors of the deformed contact surface are significantly different from that of the plane contact,which is mainly reflected in the change in the number of contact asperities and the real contact area.This study suggests that the real contact area of the interface can be altered by applying tensile and bending strains,thereby regulating its contact mechanics and conductive behavior.展开更多
The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic s...The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic strain,contact pressure,and area.The interface promotes lubrication and support when wall angles were≤40°,a 0.5 mm-thin sheet was used,and a 10 mm-large tool radius was employed.This mainly results in micro-plowing and plastic extrusion flow,leading to lower friction coefficient.However,when wall angles exceed 40°,significant plastic strain roughening occurs,leading to inadequate lubrication on the newly formed surface.Increased sheet thickness and decreased tool radius elevate contact pressure.These actions trigger micro-cutting and adhesion,potentially leading to localized scuffing and dimple tears,and higher friction coefficient.The friction mechanisms remain unaffected by the part’s plane curve features.As the forming process progresses,abrasive wear intensifies,and surface morphology evolves unfavorably for lubrication and friction reduction.展开更多
Based on the advantages of triple-wire gas indirect arc welding(TW-GIA),such as small heat input,low dilution rate,and high deposition rate,the surfacing test on Q345 steel was carried out,and the surfacing forming ch...Based on the advantages of triple-wire gas indirect arc welding(TW-GIA),such as small heat input,low dilution rate,and high deposition rate,the surfacing test on Q345 steel was carried out,and the surfacing forming characteristics of TW-GIA were studied.Results showed that due to excessive wetting angle of the weld and the limitation of the heat source mode,there was unfused defect between the weld toes of the adjacent welds.To improve the morphology of the surfacing layer,the inclined substrate surfacing process was used.As the inclination angle increases,the size of unfused defect between adjacent welds gradually decreases.When the angle of inclination is in-creased to 30°-40°,the single-layer multi-pass surfacing layer with uniform forming and available fusion between welds can be achieved.Compared with tandem double-wire arc(T-DW)surfacing,the deposition rate of TW-GIA increased by 61.49%,while the dilution rate of the base metal decreased by 71.91%.The surfacing method has the advantages of a high deposition rate and low heat input,which is benefi-cial to improve the microstructure of the surfacing layer,making the coarse columnar crystals smaller,and improving the microhardness.The average microhardness level is 233.1 HV,which is higher than the average microhardness of the T-DW surfacing layer 220.4 HV.展开更多
Iterations in optimization and numerical simulation for the sheet metal forming process may lead to extensive computation. In addition, uncertainties in materials or processing parameters may have great influence on t...Iterations in optimization and numerical simulation for the sheet metal forming process may lead to extensive computation. In addition, uncertainties in materials or processing parameters may have great influence on the design quality. A six sigma optimization method is proposed, by combining the dual response surface method （DRSM） and six sigma philosophy, to save computation cost and improve reliability and robustness of parts. Using this method, statistical technology, including the design of experiment and analysis of variance, approximate model and six sigma philosophy are integrated together to achieve improved quality. Two sheet metal forming processes are provided as examples to illustrate the proposed method.展开更多
The H13 hot-working tool steel is widely used as die material in the warm forming of Ti–6Al–4V titanium alloy sheet. However, under the heating condition, severe friction and lubricating conditions between the H13 t...The H13 hot-working tool steel is widely used as die material in the warm forming of Ti–6Al–4V titanium alloy sheet. However, under the heating condition, severe friction and lubricating conditions between the H13 tools and Ti–6Al–4V titanium alloy sheet would cause difficulty in guaranteeing forming quality. Surface modification may be used to control the level of friction force, reduce the friction wear and extend the service life of dies. In this paper, four surface modification methods（chromium plating, TiAlN coating, surface polishing and nitriding treatment）were applied to the H13 surfaces. Taking the coefficient of friction（CoF） and the wear degree as evaluation indicators, the high-temperature tribological behavior of the surface modified H13 steel was experimentally investigated under different tribological conditions. The results of this study indicate that the tribological properties of the TiAlN coating under dry friction condition are better than the others for a wide range of temperature（from room temperature to 500 C）, while there is little difference of tribological properties between different surface modifications under graphite lubricated condition, and the variation law of CoF with temperature under graphite lubricated is opposite to that under the dry friction.展开更多
Based on the foreign remanufacturing mode,which relies mainly on Part-Replacing Repair Method and Size-Changing Repair Method,China has explored and practiced the new remanufacturing mode,which relies mainly on Surfac...Based on the foreign remanufacturing mode,which relies mainly on Part-Replacing Repair Method and Size-Changing Repair Method,China has explored and practiced the new remanufacturing mode,which relies mainly on Surface Repair and Performance Improving Method.The aim of remanufacturing forming is to renew rapidly the original size of the waste components rapidly,and then improve their service performance.The advanced surface engineering technology,especially the high density heat source surface forming technology,is the important technique to carry out rapid forming.Based on the arc heat source,plasma heat source and laser heat source,three kinds of high density heat source remanufacturing forming technologies,such as high speed arc spraying forming technology,micro-arc plasma forming technology,and laser cladding forming technology,have been developed.The benefits of remanufacturing forming based on advanced surface engineering technologies are great.展开更多
Powdering/exfoliating of coatings and scratching galvanized steels and high strength steels （HSS）, are the main forms of surface damage in the forming of which result in increased die maintenance cost and scrap rate...Powdering/exfoliating of coatings and scratching galvanized steels and high strength steels （HSS）, are the main forms of surface damage in the forming of which result in increased die maintenance cost and scrap rate. In this study, a special rectangular box was developed to investigate the behavior and characteristics of surface damage in sheet metal forming （SMF） processes. U-channel forming tests were conducted to study the effect of tool hardness on surface damage in the forming of high strength steels and galvanized steels （hot-dip galvanized and galvannealed steels）. Experimental results indicate that sheet deformation mode influences the severity of surface damage in SMF and surface damage occurs easily at the regions where sheet specimen deforms under the action of compressive stress. Die corner is the position where surface damage initiates. For HSS sheet, surface damage is of major interest due to high forming pressure. The HSS and hot-dip galvanized steels show improved ability of damage-resistance with increased hardness of the forming tool. However, for galvannealed steel it is not the forming tool with the highest hardness value that performs best.展开更多
The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface qu...The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface quality in ISF.However,the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood.In this paper,the influences of process variables(i.e.tool diameter,step size and thickness of interpolators)on the forming process(e.g.surface roughness,forming force and geometric error)are investigated through a systematic experimental approach of central composite design(CCD)in two-point incremental sheet forming(TPIF).It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path.Nevertheless,the combined influence between thickness of interpolators and process parameters(tool diameter and step size)is limited.Meanwhile,the placement of interpolator has little influence on the effective forming force of blank.In addition,the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter.Finally,the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of thecontact pressure due to the increase of contact area with the unchanged contact force.Meanwhile,the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.展开更多
The manual design of addendum surfaces on common CAD platforms is very tedious which requires many trialscorrections,which will certainly a ect the construction e ciency and quality of addendum surfaces,and then a ect...The manual design of addendum surfaces on common CAD platforms is very tedious which requires many trialscorrections,which will certainly a ect the construction e ciency and quality of addendum surfaces,and then a ect the formability and quality of the workpiece in the process of sheet forming.In this paper,an automatic procedure based on parametric design method is proposed for the rapid construction of the addendum surfaces.The kernel of the parametric method is constructing boundary curves based on the shape of surfaces of workpiece and designing guide curves based on Hermite curve interpolation.By some simple parameters,the shape of the addendum surfaces could be controlled and adjusted easily.In addition,a minimum energy optimization method is employed to further optimize the constructed addendum surface.A finite element analysis for the sheet forming process is performed to evaluate the forming quality of constructed addendum surfaces.The instance illustrates that the addendum surface constructed by the proposed method could ensure both the overall smoothing of surfaces and the final forming quality,and it has a good e ect on springback after forming.This research proposes a smoothing parametric design method for addendum surfaces construction which could construct and optimize addendum surfaces rapidly.展开更多
U-channel forming tests were performed to investigate the surface topography evolvement of hot-dip galvanized(GI) and galvannealed(GA) steels and the effects of die hardness on sheet metal forming(SMF). Experimental r...U-channel forming tests were performed to investigate the surface topography evolvement of hot-dip galvanized(GI) and galvannealed(GA) steels and the effects of die hardness on sheet metal forming(SMF). Experimental results indicate that the surface roughness values of the two galvanized steels increase with the number of forming,i.e.,the surface topographies of galvanized steels are roughened in SMF. Moreover,GI steel has a better ability of damage-resistance than GA steel. The mechanisms of topography evolvement are different in the forming of GI and GA steels. Scratch is the main form of surface damage in the forming of GI steels. The severity of scratch can be decreased by increasing die hardness. GA steel results in exfoliating of the coating firstly and then severe scratching. The surface topography of galvannealed steels can be improved by increasing die hardness. However,the hardness should not be too high.展开更多
In this paper, various strategies of spiral irradiating scheme for the flame forming of a bowl shaped surface are investigated experimentally and numerically. Experimental work is performed using a flame torch integra...In this paper, various strategies of spiral irradiating scheme for the flame forming of a bowl shaped surface are investigated experimentally and numerically. Experimental work is performed using a flame torch integrated with a 2-axis CNC workstation. The ABAQUS implicit solver is used in the numerical simulation. Three different strategies of the spiral irradiating scheme are investigated for the flame forming of a bowl shaped surface. The first strategy is the Simple spi- ral irradiating scheme, the second is the Rotational spiral irradiating scheme, and the third is the Symmetrical-Rotational spiral irradiating scheme. The results show that using the Symmetrical- Rotational spiral irradiating scheme, a bowl shaped surface with the maximum deformation can be produced, followed by using the Rotational scheme, and the Simple spiral scheme. It is also concluded from the results that the spiral irradiating scheme with Symmetrical-Rotational, Rota- tional and Simple spiral schemes lead to the maximum symmetries in the produced bowl shaped surface, respectively. All the numerical results are in good agreement with the experimental ob- servations.展开更多
This paper presents an approach which enables surface modelling, mesh generation and the Finite Element (FE) analysis to be integrated together to simulate superplastic forming process for complex shaped components. T...This paper presents an approach which enables surface modelling, mesh generation and the Finite Element (FE) analysis to be integrated together to simulate superplastic forming process for complex shaped components. Techniques have been developed to generate an FE mesh over non-four-sided surface areas, the boundaries of which are Bezier curves of arbitrary degree, using a consistent expression. Theoretical evidence is given to determine the number of Bezier triangular patches required for accurately re-constructing die surfaces within a commercial FE solver. The developed techniques have been successfully used in determining the process parameters for forming a 3D rectangular box.展开更多
As the important evaluation parameters concerning the spray qualities, the porosity and surface roughness of the coatings obtained by thermal spray forming have great influence on their forming accuracy, mechanical pr...As the important evaluation parameters concerning the spray qualities, the porosity and surface roughness of the coatings obtained by thermal spray forming have great influence on their forming accuracy, mechanical properties and service lifetime. But it is difficult to predict or control the two parameters for such a highly nonlinear process. A two-dimensional simulation of coating porosity and surface roughness of nickel-aluminum alloy (Ni-5%Al) in plasma spray forming was presented, which was based on the multi-dimensional statistical behaviors of the droplets as well as the simplification and digitization of the typical splat cross sections. Further analysis involving the influence of the droplet diameters and the scanning velocities of the spray gun on the two parameters was conducted. The simulation and analysis results indicate that the porosity and surface roughness are more influenced by the droplet diameters, but less influenced by the spray gun velocities. The results will provide basis for the prediction or control of coating mechanical properties by depositing parameters.展开更多
In rotational incremental sheet forming( RISF) process,the friction heating of rotational tool could lead to local temperature rise of the sheet and cause the improvement of sheet's formability.Lightweight metal,s...In rotational incremental sheet forming( RISF) process,the friction heating of rotational tool could lead to local temperature rise of the sheet and cause the improvement of sheet's formability.Lightweight metal,such as magnesium alloy,could be deformed by RISF without additional heating. The objective of this study is to investigate the effects of forming parameters,namely,tool rotational speed,feed-rate,step size and wall angle,on the local temperature rise. Using response surface methodology and central composite design( CCD) experimental design,the significance,sequence of parameters and regression models would be analyzed with AZ31 B as the experimental material,and 3D response surface plots would be shown. Combined with actual processing conditions,the measures to improve the local temperature rise by modifying each parameter would be discussed in the end. The results showed that hierarchy of the parameters with respect to the significance of their effects on the local temperature at the side wall was: feed-rate,step size,and rotational speed,while at the bottom it was: feed-rate,step size,wall angle, and rotational speed, and no significant interaction appeared. It was found that the most significant parameter was not rotational speed,but feed-rate,followed by step size,for both test positions. In addition, the local temperature would increase by elevating step size,wall angle,rotating rate,and bringing down of feed-rate.展开更多
A non contact three dimensional measurement method is presented in this paper.This system consists of a laser triangulation probe,a probe head and a coordinate measuring machine (CMM).The measurement principle of th...A non contact three dimensional measurement method is presented in this paper.This system consists of a laser triangulation probe,a probe head and a coordinate measuring machine (CMM).The measurement principle of the system is discussed,and a system calibration method employing a reference ball is proposed.The geometric model involving four frames is established to calculate the data points based on the reading of the laser probe and position information from the CMM.A measuring experiment for gesso free form surface using this system is carried out.展开更多
The distributions of different forms of nitrogen in the surface sediments of the southern Huanghai Sea are different and affected by various factors. The contents of IEF-N, SOEF-N and TN gradually decrease eastward, a...The distributions of different forms of nitrogen in the surface sediments of the southern Huanghai Sea are different and affected by various factors. The contents of IEF-N, SOEF-N and TN gradually decrease eastward, and those of SAEF-N northward, while those of WAEF-N westward. Around the seaport of the old Huanghe (Yellow) River, the contents of both SOEF-N and TN are the highest. Among all the factors, the content of fine sediment is the predominant factor to affect the distributions of different forms of nitrogen. The contents of IEF-N, SOEF-N, and TN have visibly positive correlation with the content of fine sediments, and the correlative coefficient is 0.68, 0.58 and 0.71 respectively, showing that the contents of the three forms of nitrogen increase with those of fine sediments. The content of WAEF-N is related to that of fine sediments to a certain extent, with a correlative coefficient of 0.35; while the content of SAEF-N is not related to that of fine sediments, showing that the content of SAEF-N is not controlled by fine grain-size fractions of sediments. In addition, the distributions of different forms of nitrogen are also interacted one another, and the contents of IEF-N and SOEF-N are obviously affected by TN, while those of inorganic nitrogen (WAEF-N, SAEF-N and IEF-N) are not affected by SOEF-N and TN obviously, although they are interacted each other.展开更多
The area of the southwestern Nansha Trough is one of the most productive areas of the southern South China Sea.It is a typical semi-deep sea area of transition from shoal to abyssal zone.To understand distributions an...The area of the southwestern Nansha Trough is one of the most productive areas of the southern South China Sea.It is a typical semi-deep sea area of transition from shoal to abyssal zone.To understand distributions and roles of nitrogen forms involved in biogeochemical cycling in this area,contents of nitrogen in four extractable forms:nitrogen in ion exchangeable form(IEF-N),nitrogen in weak acid extractable form(WAEF-N),nitrogen in strong alkali extractable form(SAEF-N) and nitrogen in strong oxidation extractable form(SOEF-N),as well as in total nitrogen content(TN) in surface sediments were determined from samples collected from the cruise in April-May 1999.The study area was divided into three regions(A,B and C) in terms of clay sediment(<4 μm) content at <40%,40%-60% and >60%,respectively.Generally,region C was the richest in the nitrogen of all forms and region A the poorest,indicating that the finer the grain size is,the richer the contents of various nitrogen are.The burial efficiency of total nitrogen in surface sediments was 28.79%,indicating that more than 70% of nitrogen had been released and participated in biogeochemical recycling through sediment-water interface.展开更多
Parts with high-quality freeform surfaces have been widely used in industries,which require strict quality control during the manufacturing process.Among all the industrial inspection methods,contact measurement with ...Parts with high-quality freeform surfaces have been widely used in industries,which require strict quality control during the manufacturing process.Among all the industrial inspection methods,contact measurement with coordinate measuring machines or computer numerical control machine tool is a fundamental technique due to its high accuracy,robustness,and universality.In this paper,the existing research in the contact measurement field is systematically reviewed.First,different configurations of the measuring machines are introduced in detail,which may have influence on the corresponding sampling and inspection path generation criteria.Then,the entire inspection pipeline is divided into two stages,namely the pre-inspection and post-inspection stages.The typical methods of each sub-stage are systematically overviewed and classified,including sampling,accessibility analysis,inspection path generation,probe tip radius compensation,surface reconstruction,and uncertainty analysis.Apart from those classical research,the applications of the emerging deep learning technique in some specific tasks of measurement are introduced.Furthermore,some potential and promising trends are provided for future investigation.展开更多
基金Supported by Open Fund of Jiangsu Industrial Perception and Intelligent Manufacturing Equipment Engineering Research Center of China(Grant No.ZK21-05-04)National Natural Science Foundation of China(Grant Nos.52105360,52175328)+1 种基金Fundamental Research Funds for the Central Universities of China(Grant No.NS2022061)Prince Sattam bin Abdulaziz University of Saudi Arabia(Grant No.PSAU/2024/R/1446).
文摘In three-dimensional free-bending forming(3D-FBF),the tube is not overly constrained,and the plastic deformation behavior and forming quality of the bent tube are significantly affected by the critical structure of the forming die lining.However,the effects of die-lining structural parameters on the tube quality,and a method to determine the combination of die-lining structural parameters is yet to be devised.This study aims to propose a new framework that allows one to understand the effects of various die-lining structural parameters on tube quality and to propose the best combination of die-lining structural parameters.First,finite-element modeling is performed to simulate 3D-FBF and examine the effects of individual die-lining structures on the quality of tube formation.The simulation results show that the deformation-zone length and die gap are positively correlated with the tube-section distortion and wall-thickness variation,whereas it shows an opposite trend with respect to the bending radius.Additionally,the lining chamfer radius of the bending die and the guide lining chamfer radius minimally affect the tube forming quality.Subsequently,the optimal die-lining structure is obtained using the response-surface method.The tube cross-sectional distortion rate reduced from 2.73 to 2.53%after the die lining is optimized.Additionally,the average inner-wall thickness reduced to 1.06 mm,whereas the average outer-wall thickness increased to 0.97 mm.This paper proposes a method for optimizing the forming-die-lining mechanism and for improving the tube forming quality in 3D-FBF.
基金This work are supported by the Natural Science Foundation of China General Program(Grant No.12272157)the Natural Science Foundation of China Major Program(Grant No.12327901)+1 种基金the Fundamental Research Funds for the Central Universities(Grant No.lzujbky-2023-ey05)the 111 Project(Grant No.B14044).
文摘The contact problem of deformed rough surfaces exists widely in complex engineering structures.How to reveal the influence mechanism of surface deformation on the contact properties is a key issue in evaluating the interface performances of the engineering structures.In this paper,a contact model is established,which is suitable for tensile and bending deformed contact surfaces.Four contact forms of asperities are proposed,and their distribution characteristics are analyzed.This model reveals the mechanism of friction generation from the perspective of the force balance of asperity.The results show the contact behaviors of the deformed contact surface are significantly different from that of the plane contact,which is mainly reflected in the change in the number of contact asperities and the real contact area.This study suggests that the real contact area of the interface can be altered by applying tensile and bending strains,thereby regulating its contact mechanics and conductive behavior.
基金the support of the Key Research and Development Program of Shaanxi Province,China(No.2021GXLH-Z-049)。
文摘The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic strain,contact pressure,and area.The interface promotes lubrication and support when wall angles were≤40°,a 0.5 mm-thin sheet was used,and a 10 mm-large tool radius was employed.This mainly results in micro-plowing and plastic extrusion flow,leading to lower friction coefficient.However,when wall angles exceed 40°,significant plastic strain roughening occurs,leading to inadequate lubrication on the newly formed surface.Increased sheet thickness and decreased tool radius elevate contact pressure.These actions trigger micro-cutting and adhesion,potentially leading to localized scuffing and dimple tears,and higher friction coefficient.The friction mechanisms remain unaffected by the part’s plane curve features.As the forming process progresses,abrasive wear intensifies,and surface morphology evolves unfavorably for lubrication and friction reduction.
基金supported by the National Key Research and Development Program of China(Grant No.2022YFB4600900)the National Natural Science Foundation of China(Grant No.52175290).
文摘Based on the advantages of triple-wire gas indirect arc welding(TW-GIA),such as small heat input,low dilution rate,and high deposition rate,the surfacing test on Q345 steel was carried out,and the surfacing forming characteristics of TW-GIA were studied.Results showed that due to excessive wetting angle of the weld and the limitation of the heat source mode,there was unfused defect between the weld toes of the adjacent welds.To improve the morphology of the surfacing layer,the inclined substrate surfacing process was used.As the inclination angle increases,the size of unfused defect between adjacent welds gradually decreases.When the angle of inclination is in-creased to 30°-40°,the single-layer multi-pass surfacing layer with uniform forming and available fusion between welds can be achieved.Compared with tandem double-wire arc(T-DW)surfacing,the deposition rate of TW-GIA increased by 61.49%,while the dilution rate of the base metal decreased by 71.91%.The surfacing method has the advantages of a high deposition rate and low heat input,which is benefi-cial to improve the microstructure of the surfacing layer,making the coarse columnar crystals smaller,and improving the microhardness.The average microhardness level is 233.1 HV,which is higher than the average microhardness of the T-DW surfacing layer 220.4 HV.
基金This project is supported by National Natural Science Foundation of China (No.50475020).
文摘Iterations in optimization and numerical simulation for the sheet metal forming process may lead to extensive computation. In addition, uncertainties in materials or processing parameters may have great influence on the design quality. A six sigma optimization method is proposed, by combining the dual response surface method （DRSM） and six sigma philosophy, to save computation cost and improve reliability and robustness of parts. Using this method, statistical technology, including the design of experiment and analysis of variance, approximate model and six sigma philosophy are integrated together to achieve improved quality. Two sheet metal forming processes are provided as examples to illustrate the proposed method.
基金the National Natural Science Foundation of China(Nos.50905144 and 51275415)the Program for New Century Excellent Talents in Universitythe 111 Project (No.B08040) of China for the support given to this research
文摘The H13 hot-working tool steel is widely used as die material in the warm forming of Ti–6Al–4V titanium alloy sheet. However, under the heating condition, severe friction and lubricating conditions between the H13 tools and Ti–6Al–4V titanium alloy sheet would cause difficulty in guaranteeing forming quality. Surface modification may be used to control the level of friction force, reduce the friction wear and extend the service life of dies. In this paper, four surface modification methods（chromium plating, TiAlN coating, surface polishing and nitriding treatment）were applied to the H13 surfaces. Taking the coefficient of friction（CoF） and the wear degree as evaluation indicators, the high-temperature tribological behavior of the surface modified H13 steel was experimentally investigated under different tribological conditions. The results of this study indicate that the tribological properties of the TiAlN coating under dry friction condition are better than the others for a wide range of temperature（from room temperature to 500 C）, while there is little difference of tribological properties between different surface modifications under graphite lubricated condition, and the variation law of CoF with temperature under graphite lubricated is opposite to that under the dry friction.
文摘Based on the foreign remanufacturing mode,which relies mainly on Part-Replacing Repair Method and Size-Changing Repair Method,China has explored and practiced the new remanufacturing mode,which relies mainly on Surface Repair and Performance Improving Method.The aim of remanufacturing forming is to renew rapidly the original size of the waste components rapidly,and then improve their service performance.The advanced surface engineering technology,especially the high density heat source surface forming technology,is the important technique to carry out rapid forming.Based on the arc heat source,plasma heat source and laser heat source,three kinds of high density heat source remanufacturing forming technologies,such as high speed arc spraying forming technology,micro-arc plasma forming technology,and laser cladding forming technology,have been developed.The benefits of remanufacturing forming based on advanced surface engineering technologies are great.
基金supported by the National Natural Science Foundation of China under grant No. 50605043
文摘Powdering/exfoliating of coatings and scratching galvanized steels and high strength steels （HSS）, are the main forms of surface damage in the forming of which result in increased die maintenance cost and scrap rate. In this study, a special rectangular box was developed to investigate the behavior and characteristics of surface damage in sheet metal forming （SMF） processes. U-channel forming tests were conducted to study the effect of tool hardness on surface damage in the forming of high strength steels and galvanized steels （hot-dip galvanized and galvannealed steels）. Experimental results indicate that sheet deformation mode influences the severity of surface damage in SMF and surface damage occurs easily at the regions where sheet specimen deforms under the action of compressive stress. Die corner is the position where surface damage initiates. For HSS sheet, surface damage is of major interest due to high forming pressure. The HSS and hot-dip galvanized steels show improved ability of damage-resistance with increased hardness of the forming tool. However, for galvannealed steel it is not the forming tool with the highest hardness value that performs best.
基金support from the National Natural Science Foundation of China(51575028)National Natural Science Foundation of China(51605258)the Fundamental Research Funds for the Central Universities of China(YWF-18-BJ-J-75)。
文摘The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface quality in ISF.However,the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood.In this paper,the influences of process variables(i.e.tool diameter,step size and thickness of interpolators)on the forming process(e.g.surface roughness,forming force and geometric error)are investigated through a systematic experimental approach of central composite design(CCD)in two-point incremental sheet forming(TPIF).It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path.Nevertheless,the combined influence between thickness of interpolators and process parameters(tool diameter and step size)is limited.Meanwhile,the placement of interpolator has little influence on the effective forming force of blank.In addition,the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter.Finally,the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of thecontact pressure due to the increase of contact area with the unchanged contact force.Meanwhile,the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.
基金Supported by National Natural Science Foundation of China(Grant No.61471024)National Natural Science Foundation for Young Scientists of China(Grant No.51705469).
文摘The manual design of addendum surfaces on common CAD platforms is very tedious which requires many trialscorrections,which will certainly a ect the construction e ciency and quality of addendum surfaces,and then a ect the formability and quality of the workpiece in the process of sheet forming.In this paper,an automatic procedure based on parametric design method is proposed for the rapid construction of the addendum surfaces.The kernel of the parametric method is constructing boundary curves based on the shape of surfaces of workpiece and designing guide curves based on Hermite curve interpolation.By some simple parameters,the shape of the addendum surfaces could be controlled and adjusted easily.In addition,a minimum energy optimization method is employed to further optimize the constructed addendum surface.A finite element analysis for the sheet forming process is performed to evaluate the forming quality of constructed addendum surfaces.The instance illustrates that the addendum surface constructed by the proposed method could ensure both the overall smoothing of surfaces and the final forming quality,and it has a good e ect on springback after forming.This research proposes a smoothing parametric design method for addendum surfaces construction which could construct and optimize addendum surfaces rapidly.
基金Project(50605043) supported by the National Natural Science Foundation of China
文摘U-channel forming tests were performed to investigate the surface topography evolvement of hot-dip galvanized(GI) and galvannealed(GA) steels and the effects of die hardness on sheet metal forming(SMF). Experimental results indicate that the surface roughness values of the two galvanized steels increase with the number of forming,i.e.,the surface topographies of galvanized steels are roughened in SMF. Moreover,GI steel has a better ability of damage-resistance than GA steel. The mechanisms of topography evolvement are different in the forming of GI and GA steels. Scratch is the main form of surface damage in the forming of GI steels. The severity of scratch can be decreased by increasing die hardness. GA steel results in exfoliating of the coating firstly and then severe scratching. The surface topography of galvannealed steels can be improved by increasing die hardness. However,the hardness should not be too high.
文摘In this paper, various strategies of spiral irradiating scheme for the flame forming of a bowl shaped surface are investigated experimentally and numerically. Experimental work is performed using a flame torch integrated with a 2-axis CNC workstation. The ABAQUS implicit solver is used in the numerical simulation. Three different strategies of the spiral irradiating scheme are investigated for the flame forming of a bowl shaped surface. The first strategy is the Simple spi- ral irradiating scheme, the second is the Rotational spiral irradiating scheme, and the third is the Symmetrical-Rotational spiral irradiating scheme. The results show that using the Symmetrical- Rotational spiral irradiating scheme, a bowl shaped surface with the maximum deformation can be produced, followed by using the Rotational scheme, and the Simple spiral scheme. It is also concluded from the results that the spiral irradiating scheme with Symmetrical-Rotational, Rota- tional and Simple spiral schemes lead to the maximum symmetries in the produced bowl shaped surface, respectively. All the numerical results are in good agreement with the experimental ob- servations.
基金The work is supported by Shanxi Foundation for scholars returned from abroad
文摘This paper presents an approach which enables surface modelling, mesh generation and the Finite Element (FE) analysis to be integrated together to simulate superplastic forming process for complex shaped components. Techniques have been developed to generate an FE mesh over non-four-sided surface areas, the boundaries of which are Bezier curves of arbitrary degree, using a consistent expression. Theoretical evidence is given to determine the number of Bezier triangular patches required for accurately re-constructing die surfaces within a commercial FE solver. The developed techniques have been successfully used in determining the process parameters for forming a 3D rectangular box.
基金Project(50675072) supported by the National Natural Science Foundation of ChinaProject(2006J0165) supported by the Natural Science Foundation of Fujian Province of ChinaProject(20062178) supported by the Natural Science Foundation of Liaoning Province of China
文摘As the important evaluation parameters concerning the spray qualities, the porosity and surface roughness of the coatings obtained by thermal spray forming have great influence on their forming accuracy, mechanical properties and service lifetime. But it is difficult to predict or control the two parameters for such a highly nonlinear process. A two-dimensional simulation of coating porosity and surface roughness of nickel-aluminum alloy (Ni-5%Al) in plasma spray forming was presented, which was based on the multi-dimensional statistical behaviors of the droplets as well as the simplification and digitization of the typical splat cross sections. Further analysis involving the influence of the droplet diameters and the scanning velocities of the spray gun on the two parameters was conducted. The simulation and analysis results indicate that the porosity and surface roughness are more influenced by the droplet diameters, but less influenced by the spray gun velocities. The results will provide basis for the prediction or control of coating mechanical properties by depositing parameters.
基金National Natural Science Foundation of China(No.51205217)the Project of Shandong Province Higher Educational Science and Technology Program,China(No.J10LD13)+1 种基金the Taishan Scholar Project of Shandong Province,China(No.ts 201511038)the Key Research Project of Shandong Province,China(No.2016ZDJS02A15)
文摘In rotational incremental sheet forming( RISF) process,the friction heating of rotational tool could lead to local temperature rise of the sheet and cause the improvement of sheet's formability.Lightweight metal,such as magnesium alloy,could be deformed by RISF without additional heating. The objective of this study is to investigate the effects of forming parameters,namely,tool rotational speed,feed-rate,step size and wall angle,on the local temperature rise. Using response surface methodology and central composite design( CCD) experimental design,the significance,sequence of parameters and regression models would be analyzed with AZ31 B as the experimental material,and 3D response surface plots would be shown. Combined with actual processing conditions,the measures to improve the local temperature rise by modifying each parameter would be discussed in the end. The results showed that hierarchy of the parameters with respect to the significance of their effects on the local temperature at the side wall was: feed-rate,step size,and rotational speed,while at the bottom it was: feed-rate,step size,wall angle, and rotational speed, and no significant interaction appeared. It was found that the most significant parameter was not rotational speed,but feed-rate,followed by step size,for both test positions. In addition, the local temperature would increase by elevating step size,wall angle,rotating rate,and bringing down of feed-rate.
基金Supported by"863"High Technology Development Comittee ofChina (No."863"- 51 1 - 942 - 0 2 4 ) National Natural Science Foun-dation of China (No.50 0 750 64)
文摘A non contact three dimensional measurement method is presented in this paper.This system consists of a laser triangulation probe,a probe head and a coordinate measuring machine (CMM).The measurement principle of the system is discussed,and a system calibration method employing a reference ball is proposed.The geometric model involving four frames is established to calculate the data points based on the reading of the laser probe and position information from the CMM.A measuring experiment for gesso free form surface using this system is carried out.
文摘The distributions of different forms of nitrogen in the surface sediments of the southern Huanghai Sea are different and affected by various factors. The contents of IEF-N, SOEF-N and TN gradually decrease eastward, and those of SAEF-N northward, while those of WAEF-N westward. Around the seaport of the old Huanghe (Yellow) River, the contents of both SOEF-N and TN are the highest. Among all the factors, the content of fine sediment is the predominant factor to affect the distributions of different forms of nitrogen. The contents of IEF-N, SOEF-N, and TN have visibly positive correlation with the content of fine sediments, and the correlative coefficient is 0.68, 0.58 and 0.71 respectively, showing that the contents of the three forms of nitrogen increase with those of fine sediments. The content of WAEF-N is related to that of fine sediments to a certain extent, with a correlative coefficient of 0.35; while the content of SAEF-N is not related to that of fine sediments, showing that the content of SAEF-N is not controlled by fine grain-size fractions of sediments. In addition, the distributions of different forms of nitrogen are also interacted one another, and the contents of IEF-N and SOEF-N are obviously affected by TN, while those of inorganic nitrogen (WAEF-N, SAEF-N and IEF-N) are not affected by SOEF-N and TN obviously, although they are interacted each other.
基金Supported by the National Basic Research Program of China (973 Program, No. 2007CB407305)Qingdao Special Project for Outstanding Scientists (No.05-2-JC-90)the 100 Talents Project of Chinese Academy of Sciences (No.2003-202)
文摘The area of the southwestern Nansha Trough is one of the most productive areas of the southern South China Sea.It is a typical semi-deep sea area of transition from shoal to abyssal zone.To understand distributions and roles of nitrogen forms involved in biogeochemical cycling in this area,contents of nitrogen in four extractable forms:nitrogen in ion exchangeable form(IEF-N),nitrogen in weak acid extractable form(WAEF-N),nitrogen in strong alkali extractable form(SAEF-N) and nitrogen in strong oxidation extractable form(SOEF-N),as well as in total nitrogen content(TN) in surface sediments were determined from samples collected from the cruise in April-May 1999.The study area was divided into three regions(A,B and C) in terms of clay sediment(<4 μm) content at <40%,40%-60% and >60%,respectively.Generally,region C was the richest in the nitrogen of all forms and region A the poorest,indicating that the finer the grain size is,the richer the contents of various nitrogen are.The burial efficiency of total nitrogen in surface sediments was 28.79%,indicating that more than 70% of nitrogen had been released and participated in biogeochemical recycling through sediment-water interface.
基金partially supported by the Natural Science Foundation of Shanghai(Grant No.22ZR1435200)the National Natural Science Foundation of China(Grant No.52075337)the Open Research Fund of State Key Laboratory of Digital Manufacturing and Equipment Technology,HUST(Grant No.DMETKF2022010)。
文摘Parts with high-quality freeform surfaces have been widely used in industries,which require strict quality control during the manufacturing process.Among all the industrial inspection methods,contact measurement with coordinate measuring machines or computer numerical control machine tool is a fundamental technique due to its high accuracy,robustness,and universality.In this paper,the existing research in the contact measurement field is systematically reviewed.First,different configurations of the measuring machines are introduced in detail,which may have influence on the corresponding sampling and inspection path generation criteria.Then,the entire inspection pipeline is divided into two stages,namely the pre-inspection and post-inspection stages.The typical methods of each sub-stage are systematically overviewed and classified,including sampling,accessibility analysis,inspection path generation,probe tip radius compensation,surface reconstruction,and uncertainty analysis.Apart from those classical research,the applications of the emerging deep learning technique in some specific tasks of measurement are introduced.Furthermore,some potential and promising trends are provided for future investigation.
