An intelligent response surface methodology (IRSM) was proposed to achieve the most competitive metal forming products, in which artificial intelligence technologies are introduced into the optimization process. It is...An intelligent response surface methodology (IRSM) was proposed to achieve the most competitive metal forming products, in which artificial intelligence technologies are introduced into the optimization process. It is used as simple and inexpensive replacement for computationally expensive simulation model. In IRSM, the optimal design space can be reduced greatly without any prior information about function distribution. Also, by identifying the approximation error region, new design points can be supplemented correspondingly to improve the response surface model effectively. The procedure is iterated until the accuracy reaches the desired threshold value. Thus, the global optimization can be performed based on this substitute model. Finally, we present an optimization design example about roll forming of a "U" channel product.展开更多
In order to continuously simulate multi-pass plate rolling process,a 3-D elastic hollow-roll model was proposed and an auto mesh-refining module with data passing was developed and integrated with FE software,Marc.The...In order to continuously simulate multi-pass plate rolling process,a 3-D elastic hollow-roll model was proposed and an auto mesh-refining module with data passing was developed and integrated with FE software,Marc.The hollow-roll model has equivalent stiffness of bending resistance and deformation to the real solid and much less meshes,so the computational time is greatly reduced.Based on these,the factors influencing plate profile,such as the roll-bending force,initial crown,thermal crown and heat transfer during rolling and inter-pass cooling can be taken into account in the simulation.The auto mesh-refining module with data passing can automatically refine and re-number elements and transfer the nodal and elemental results to the new meshes.Furthermore,the 3-D modeling routine is parametrically developed and can be run independently of Marc pre-processing program.A seven-pass industrial hot rolling process was continuously simulated to validate the accuracy of model.By comparison of the calculated results with the industrial measured data,the rolling force,temperature and plate profile are in good accordance with the measured ones.展开更多
The microstractural evolution of microalloyed steel during hot forging process was investigated using physical simulation experiments. The dynamic recrystallized fraction was described by modifying Avrami＇s equation,...The microstractural evolution of microalloyed steel during hot forging process was investigated using physical simulation experiments. The dynamic recrystallized fraction was described by modifying Avrami＇s equation, the parameters of which were determined by single hit compression tests. Double hit compression tests were performed to model the equation describing the static recrystallized fraction, and the obtained predicted values were in good agreement with the measured values. Austenitic grain growth was modeled as： Dinc^5 = D0^5 ＋ 1.6 × 10^32t·exp （ -716870/RT ） using isothermal tests. Furthermore, an equation describing the dynamic recrystallized grain size was given as Ddyn=3771·Z^-0.2. The models of microstructural evolution could be applied to the numerical simulation of hot forging.展开更多
Springback is caused by the redistribution of stress in sheet material after the tooling is removed. Precise prediction of sheet springback is very important in die design. Based on Hill’s yielding criterion and plan...Springback is caused by the redistribution of stress in sheet material after the tooling is removed. Precise prediction of sheet springback is very important in die design. Based on Hill’s yielding criterion and plane strain condition, an analytical model is proposed in this paper which takes into account the effects of contact pressure, the length of bending arm between the punch and die, transverse stress, neutral surface shifting and sheet thickness thinning on the sheet springback of V-bending. The predicted results by this analytical model indicated that the contact pressure and transverse stress have much effect on the springback when the bending ratio (the ratio of punch radius to sheet thickness) is less than five. The contact pressure declined when the length of bending arm goes up, which means that shorter length of bending arm will result in larger springback. The effect of neutral surface shifting on the springback is less than that of contact pressure and decreases with the bending ratio. However, this research showed that the influence of thickness thinning on the springback can be ignored. Comparison with finite element method (FEM) simu-lating results shows that the predicted results by the analytical model accord well with simulation results by FEM. In addition to that, the bending ability—the limit bending ratio for a given sheet thickness and material properties was also determined.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
Based on crystal plasticity theory and surface layer model, relation of flow stress to billet dimension and grain size was built, and rationality of derived relation was verified with tensile tests of different size b...Based on crystal plasticity theory and surface layer model, relation of flow stress to billet dimension and grain size was built, and rationality of derived relation was verified with tensile tests of different size billets. With derived expressions, relation of decreasing flow stress scale effect to billet dimension, grain size as well as billet shape was discussed and predicted. The results show that flow stress is proportional to billet size; with decrease of grain size, flow stress is less influenced by billet dimension. When both cross section area and grain size are same, flow stress decrease of rectangular section billet or sheet is larger than that of circular section billet.展开更多
To understand the forming behaviour of magnesium alloys, the upsetting test of Mg alloys at evaluated temperature was conducted. It is found that Mg alloys are brittle at temperatures below 200 ℃. When temperature is...To understand the forming behaviour of magnesium alloys, the upsetting test of Mg alloys at evaluated temperature was conducted. It is found that Mg alloys are brittle at temperatures below 200 ℃. When temperature is higher than 400 ℃, Mg alloy is not suitable for forging because of heavy oxidation. Mg alloy shows an excellent workability at temperatures from 250 to 400 ℃. Because in warm forging the flow stress decreases with increasing strain, which is so called work softening, no appropriate material formulation is available for Mg alloys. For the evaluation of flow stress of Mg alloys in warm forging processes, a formula is derived by analyzing the stress data measured at various temperatures in upsetting test. It is demonstrated that the formula fits the flow stress obtained from experiment.展开更多
The accuracy of nucleation parameter is a critical factor in the simulation of microstructural evolution during dynamic recrystallization(DRX).Based on the flow stress curve under hot deformation conditions,a new appr...The accuracy of nucleation parameter is a critical factor in the simulation of microstructural evolution during dynamic recrystallization(DRX).Based on the flow stress curve under hot deformation conditions,a new approach is proposed to identify the nucleation parameter during DRX.In this approach,a cellular automaton(CA) model is applied to quantitatively simulate the microstructural evolution and flow stress during hot deformation;and adaptive response surface method(ARSM) is applied as optimization model to provide input parameters to CA model and evaluate the outputs of the latter.By taking an oxygen-free high-conductivity(OFHC) copper as an example,the good agreement between the simulation results and the experimental observations demonstrates the availability of the proposed method.展开更多
Based on hot compression tests by a Gleeble-1500D thermo-mechanical simulator, the flow stress model and microstructure evolution model for SA508-3 steel were established through the classical theories on work hardeni...Based on hot compression tests by a Gleeble-1500D thermo-mechanical simulator, the flow stress model and microstructure evolution model for SA508-3 steel were established through the classical theories on work hardening and softening. The developed models were integrated into 3D thermal-mechanical coupled rigid plastic finite element software DEFORM3D. The inhomogeneous hot deformation （IHD） experiments of SA508 3 steel were designed and carried out. Meanwhile, numerical simulation was implemented to investigate the effect of temperature, strain and strain rate on microstructure during IHD process through measuring grain sizes at given positions. The simulated grain sizes were basically in agreement with the experimental ones. The results of experiment and simulation demonstrated that temperature is the main factor for the initiation of dynamic recrystallization （DRX）, and higher temperature means lower critical strain so that DRX can be facilitated to obtain uniform fine microstructure.展开更多
The inverse heat conduction method is one of methods to identify the casting simulation parameters. A new inverse method was presented according to the Tikhonov regularization theory. One appropriate regularized funct...The inverse heat conduction method is one of methods to identify the casting simulation parameters. A new inverse method was presented according to the Tikhonov regularization theory. One appropriate regularized functional was established, and the functional was solved by the sensitivity coefficient and Newtonaphson iteration method. Moreover, the orthogonal experimental design was used to estimate the appropriate initial value and variation domain of each variable to decrease the number of iteration and improve the identification accuracy and efficiency. It illustrated a detailed case of AlSiTMg sand mold casting and the temperature measurement experiment was done. The physical properties of sand mold and the interracial heat transfer coefficient were identified at the meantime. The results indicated that the new regularization method was efficient in overcoming the ill-posedness of the inverse heat conduction problem and improving the stability and accuracy of the solutions.展开更多
The dynamic recrystallization behavior of microalloyed forged steel was investigated with a compression test in the temperature range of 1 223-1 473 K and a strain rate of 0. 01-5 s^-1. Activation energy was calculate...The dynamic recrystallization behavior of microalloyed forged steel was investigated with a compression test in the temperature range of 1 223-1 473 K and a strain rate of 0. 01-5 s^-1. Activation energy was calculated to be 305.9 kJ/mol by regression analysis. Modeling equations were developed to represent the dynamic recrystallization volume fraction and grain size. Parameters of the modeling equations were determined as a function of the Zener-Hollomon parameter. The developed modeling equation will be combined with finite element modeling to predict microstructural change during the hot forging processing.展开更多
Waves occurring in cold-rolled plates or sheets can be divided into longitudinal and transverse waves. Classical leveling theories merely solve the problem of longitudinal waves, while no well accepted method can be e...Waves occurring in cold-rolled plates or sheets can be divided into longitudinal and transverse waves. Classical leveling theories merely solve the problem of longitudinal waves, while no well accepted method can be employed for transverse waves. In order to investigate the essential deformation law of leveling for plates with transverse waves, a 2.5-dimensional （2.5- D） analytical approach was proposed. In this model, the plate was transversely divided into some strips with equal width; the strips are considered to be in the state of plane strain and each group of adjacent strips are assumed to be deformation compatible under stress. After calculation, the bending deformation of each strip and the leveling effect of overall plate were obtained by comprehensNe consideration of various strips along with the width. Bending of roller is a main approach to eliminate the transverse waves, which is widely accepted by the industry, but the essential effect of bending of roller on the deformation of plates and the calculation of bending of roller are unknown. According to the 2.5-D analytical model, it can be found that, for plates, it is neutral plane offsetting and middle plane elongation or contraction under inner stress that can effectively improve plate shape. Taking double side waves as an example, the appropriate values of bending of roller were obtained by the 2.5-D analytical model related to different initial unevenness, which was applicable to the current on-line adjusting of bending of roller in rolling industry.展开更多
An adaptive finite element-element-free Galerkin (FE-EFG) coupling method is proposed and developed for the numerical simulation of bulk metal forming processes. This approach is able to adaptively convert distorted F...An adaptive finite element-element-free Galerkin (FE-EFG) coupling method is proposed and developed for the numerical simulation of bulk metal forming processes. This approach is able to adaptively convert distorted FE elements to EFG domain in analysis. A new scheme to implement adaptive conversion and coupling is presented. The coupling method takes both advantages of finite element method (FEM) and meshless methods. It is capable of handling large deformations with no need of remeshing procedures, while it is computationally more efficient than those full meshless methods. The effectiveness of the proposed method is demonstrated with the numerical simulations of the bulk metal forming processes including forging and extrusion.展开更多
The theory of grey systems is a new technique for performing prediction, relational analysis and decision making in many areas. In this paper, the use of grey relational analysis for optimizing the square hole flangin...The theory of grey systems is a new technique for performing prediction, relational analysis and decision making in many areas. In this paper, the use of grey relational analysis for optimizing the square hole flanging process parameters with considerations of the multiple response (the average flanging height, regular flanging and maximum strain) is introduced. Various flanging parameters, such as the blank inner radius rb, blank inner width B0, are considered. An orthogonal array is used for the experimental design. Multiple response values are obtained using finite element analysis (FEA). Optimal process parameters are determined by the grey relational grade obtained from the grey relational analysis for multi-performance characteristics (flanging height, regular flanging and maximum strain). Analysis of variance (ANOVA) for the grey relational grade is implemented. The results showed good agreement with the experiment result. Grey relational analysis can be applied in multiple response optimi-zation designs.展开更多
The hot deformation behavior of AA6063 aluminium alloy has been investigated by means of compression tests at temperatures between 400 and 520℃, and strain rates ranging from 2.5 to 10 s^-1. Owing to the barreling, t...The hot deformation behavior of AA6063 aluminium alloy has been investigated by means of compression tests at temperatures between 400 and 520℃, and strain rates ranging from 2.5 to 10 s^-1. Owing to the barreling, the theoretical model on the basis of Hills general method is used to calculate the flow stress of a cylindrical specimen under uniaxial simple compression so as to consider the friction effect at the die-specimen interface. A method of evaluating the friction coefficient by combining compression tests with the finite element method is presented. The real flow behavior of AA6063 aluminium alloy can be described with sinh-Arrhenius equation. The hot deformation activation energy Q derived from the corrected stress and strain data is 232. 350 kJ/mol.展开更多
A modified cellular automata （CA） model of dynamic recrystallization （DRX） and a flow stress-based nucleation parameter identification method have been developed. In the method, the modified CA model, which takes ...A modified cellular automata （CA） model of dynamic recrystallization （DRX） and a flow stress-based nucleation parameter identification method have been developed. In the method, the modified CA model, which takes the role of deformation degree on nucleation behavior into consideration, is coupled with an adaptive response surface model （ARSM） to search for the optimum nucleation parameter. The DRX behavior of an oxygen free high conductivity （OFHC） copper with different initial grain sizes has been taken as an example to validate the model. Good agreement is found between the simulated and the experimental results, which demonstrates that the new method can effectively improve the simulation accuracy.展开更多
A full distribution CNC system based on SERCOS bus is studied in accordance with the limitations of traditional PC-based motion card. The conventional PC-based motion control card is dispersed into several autonomous ...A full distribution CNC system based on SERCOS bus is studied in accordance with the limitations of traditional PC-based motion card. The conventional PC-based motion control card is dispersed into several autonomous intelligent servo-control units with the function of servo driver. The autonomous intelligent servocontrol units realize the loop control of position, velocity and current. Interpolation computation is completed in PC and the computational results are transferred to every autonomous intelligent servo-control unit by high speed SERCOS bus. Software or hardware synchronization technology is used to ensure all servomotors are successive and synchronously running. The communication and synchronization technology of SERCOS are also researched and the autonomous intelligent servo-control card is developed byself. Finally, the experiment of circle contour process on a prototype system proves the feasibility.展开更多
An integrated optimization strategy based on Kriging model and multi-objective particle swarm optimization(PSO) algorithm was constructed.As a new surrogate model technology,Kriging model has better fitting precision ...An integrated optimization strategy based on Kriging model and multi-objective particle swarm optimization(PSO) algorithm was constructed.As a new surrogate model technology,Kriging model has better fitting precision for nonlinear problem.The Kriging model was adopted to replace computer aided engineering(CAE) simulation as fitness function of multi-objective PSO algorithm,and the computation cost can be reduced greatly.By introducing multi-objective handling mechanism of crowding distance and mutation operator to multiobjective PSO algorithm,the entire Pareto front can be approximated better.It is shown that the multi-objective optimization strategy can get higher solving accuracy and computation efficiency under small sample.展开更多
To accurately predict the occurrence of ductile fracture in metal forming processes, the Gurson-Tvergaard （GT） porous material model with optimized adjustment parameters is adopted to analyze the macroscopic stresss...To accurately predict the occurrence of ductile fracture in metal forming processes, the Gurson-Tvergaard （GT） porous material model with optimized adjustment parameters is adopted to analyze the macroscopic stressstrain response, and a practical void nucleation law is proposed with a few material constants for engineering applications. Mechanical and metallographic analyses of uniaxial tension, torsion and upsetting experiments are performed. According to the character of the metal forming processes, the basic mechanisms of ductile fracture are divided into two modes： tension-type mode and shear-type mode. A unified fracture criterion is proposed for wide applicable range, and the comparison of experimental results with numerical analysis results confirms the validity of the newly proposed ductile fracture criterion based on the GT porous material model.展开更多
Methods used for digital ship design were studied and formed the basis of a proposed frame model suitable for ship construction modeling. Based on 3-D modeling software, a digital design system for hull structures was...Methods used for digital ship design were studied and formed the basis of a proposed frame model suitable for ship construction modeling. Based on 3-D modeling software, a digital design system for hull structures was developed. Basic software systems for modeling, modifying, and assembly simulation were developed. The system has good compatibility, and models created by it can be saved in different 3-D file formats, and 2D engineering drawings can be output directly. The model can be modified dynamically, overcoming the necessity of repeated modifications during hull structural design. Through operations such as model construction, intervention inspection, and collision detection, problems can be identified and modified during the hull structural design stage. Technologies for centralized control of the system, database management, and 3-D digital design are integrated into this digital model in the preliminary design stage of shipbuilding.展开更多
文摘An intelligent response surface methodology (IRSM) was proposed to achieve the most competitive metal forming products, in which artificial intelligence technologies are introduced into the optimization process. It is used as simple and inexpensive replacement for computationally expensive simulation model. In IRSM, the optimal design space can be reduced greatly without any prior information about function distribution. Also, by identifying the approximation error region, new design points can be supplemented correspondingly to improve the response surface model effectively. The procedure is iterated until the accuracy reaches the desired threshold value. Thus, the global optimization can be performed based on this substitute model. Finally, we present an optimization design example about roll forming of a "U" channel product.
基金Project(20050248007) supported by the Specialized Research Fund for the Doctoral Program of Higher Education of China
文摘In order to continuously simulate multi-pass plate rolling process,a 3-D elastic hollow-roll model was proposed and an auto mesh-refining module with data passing was developed and integrated with FE software,Marc.The hollow-roll model has equivalent stiffness of bending resistance and deformation to the real solid and much less meshes,so the computational time is greatly reduced.Based on these,the factors influencing plate profile,such as the roll-bending force,initial crown,thermal crown and heat transfer during rolling and inter-pass cooling can be taken into account in the simulation.The auto mesh-refining module with data passing can automatically refine and re-number elements and transfer the nodal and elemental results to the new meshes.Furthermore,the 3-D modeling routine is parametrically developed and can be run independently of Marc pre-processing program.A seven-pass industrial hot rolling process was continuously simulated to validate the accuracy of model.By comparison of the calculated results with the industrial measured data,the rolling force,temperature and plate profile are in good accordance with the measured ones.
基金This work was supported by the National Natural Science Foundation of China （No. 50275094）.
文摘The microstractural evolution of microalloyed steel during hot forging process was investigated using physical simulation experiments. The dynamic recrystallized fraction was described by modifying Avrami＇s equation, the parameters of which were determined by single hit compression tests. Double hit compression tests were performed to model the equation describing the static recrystallized fraction, and the obtained predicted values were in good agreement with the measured values. Austenitic grain growth was modeled as： Dinc^5 = D0^5 ＋ 1.6 × 10^32t·exp （ -716870/RT ） using isothermal tests. Furthermore, an equation describing the dynamic recrystallized grain size was given as Ddyn=3771·Z^-0.2. The models of microstructural evolution could be applied to the numerical simulation of hot forging.
文摘Springback is caused by the redistribution of stress in sheet material after the tooling is removed. Precise prediction of sheet springback is very important in die design. Based on Hill’s yielding criterion and plane strain condition, an analytical model is proposed in this paper which takes into account the effects of contact pressure, the length of bending arm between the punch and die, transverse stress, neutral surface shifting and sheet thickness thinning on the sheet springback of V-bending. The predicted results by this analytical model indicated that the contact pressure and transverse stress have much effect on the springback when the bending ratio (the ratio of punch radius to sheet thickness) is less than five. The contact pressure declined when the length of bending arm goes up, which means that shorter length of bending arm will result in larger springback. The effect of neutral surface shifting on the springback is less than that of contact pressure and decreases with the bending ratio. However, this research showed that the influence of thickness thinning on the springback can be ignored. Comparison with finite element method (FEM) simu-lating results shows that the predicted results by the analytical model accord well with simulation results by FEM. In addition to that, the bending ability—the limit bending ratio for a given sheet thickness and material properties was also determined.
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.
文摘Based on crystal plasticity theory and surface layer model, relation of flow stress to billet dimension and grain size was built, and rationality of derived relation was verified with tensile tests of different size billets. With derived expressions, relation of decreasing flow stress scale effect to billet dimension, grain size as well as billet shape was discussed and predicted. The results show that flow stress is proportional to billet size; with decrease of grain size, flow stress is less influenced by billet dimension. When both cross section area and grain size are same, flow stress decrease of rectangular section billet or sheet is larger than that of circular section billet.
文摘To understand the forming behaviour of magnesium alloys, the upsetting test of Mg alloys at evaluated temperature was conducted. It is found that Mg alloys are brittle at temperatures below 200 ℃. When temperature is higher than 400 ℃, Mg alloy is not suitable for forging because of heavy oxidation. Mg alloy shows an excellent workability at temperatures from 250 to 400 ℃. Because in warm forging the flow stress decreases with increasing strain, which is so called work softening, no appropriate material formulation is available for Mg alloys. For the evaluation of flow stress of Mg alloys in warm forging processes, a formula is derived by analyzing the stress data measured at various temperatures in upsetting test. It is demonstrated that the formula fits the flow stress obtained from experiment.
基金Project(2006CB705401) supported by the National Basic Research Program of China
文摘The accuracy of nucleation parameter is a critical factor in the simulation of microstructural evolution during dynamic recrystallization(DRX).Based on the flow stress curve under hot deformation conditions,a new approach is proposed to identify the nucleation parameter during DRX.In this approach,a cellular automaton(CA) model is applied to quantitatively simulate the microstructural evolution and flow stress during hot deformation;and adaptive response surface method(ARSM) is applied as optimization model to provide input parameters to CA model and evaluate the outputs of the latter.By taking an oxygen-free high-conductivity(OFHC) copper as an example,the good agreement between the simulation results and the experimental observations demonstrates the availability of the proposed method.
基金Item Sponsored by National Basic Research Program(973Program)of China(2011CB012903)National Natural Science Foundation of China(51075270)
文摘Based on hot compression tests by a Gleeble-1500D thermo-mechanical simulator, the flow stress model and microstructure evolution model for SA508-3 steel were established through the classical theories on work hardening and softening. The developed models were integrated into 3D thermal-mechanical coupled rigid plastic finite element software DEFORM3D. The inhomogeneous hot deformation （IHD） experiments of SA508 3 steel were designed and carried out. Meanwhile, numerical simulation was implemented to investigate the effect of temperature, strain and strain rate on microstructure during IHD process through measuring grain sizes at given positions. The simulated grain sizes were basically in agreement with the experimental ones. The results of experiment and simulation demonstrated that temperature is the main factor for the initiation of dynamic recrystallization （DRX）, and higher temperature means lower critical strain so that DRX can be facilitated to obtain uniform fine microstructure.
文摘The inverse heat conduction method is one of methods to identify the casting simulation parameters. A new inverse method was presented according to the Tikhonov regularization theory. One appropriate regularized functional was established, and the functional was solved by the sensitivity coefficient and Newtonaphson iteration method. Moreover, the orthogonal experimental design was used to estimate the appropriate initial value and variation domain of each variable to decrease the number of iteration and improve the identification accuracy and efficiency. It illustrated a detailed case of AlSiTMg sand mold casting and the temperature measurement experiment was done. The physical properties of sand mold and the interracial heat transfer coefficient were identified at the meantime. The results indicated that the new regularization method was efficient in overcoming the ill-posedness of the inverse heat conduction problem and improving the stability and accuracy of the solutions.
基金National Natural Science Foundation of China (50275094)
文摘The dynamic recrystallization behavior of microalloyed forged steel was investigated with a compression test in the temperature range of 1 223-1 473 K and a strain rate of 0. 01-5 s^-1. Activation energy was calculated to be 305.9 kJ/mol by regression analysis. Modeling equations were developed to represent the dynamic recrystallization volume fraction and grain size. Parameters of the modeling equations were determined as a function of the Zener-Hollomon parameter. The developed modeling equation will be combined with finite element modeling to predict microstructural change during the hot forging processing.
基金Sponsored by National Science and Technology Major Project of China(2012ZX04012011)National Natural Science Foundation of China(51375306)
文摘Waves occurring in cold-rolled plates or sheets can be divided into longitudinal and transverse waves. Classical leveling theories merely solve the problem of longitudinal waves, while no well accepted method can be employed for transverse waves. In order to investigate the essential deformation law of leveling for plates with transverse waves, a 2.5-dimensional （2.5- D） analytical approach was proposed. In this model, the plate was transversely divided into some strips with equal width; the strips are considered to be in the state of plane strain and each group of adjacent strips are assumed to be deformation compatible under stress. After calculation, the bending deformation of each strip and the leveling effect of overall plate were obtained by comprehensNe consideration of various strips along with the width. Bending of roller is a main approach to eliminate the transverse waves, which is widely accepted by the industry, but the essential effect of bending of roller on the deformation of plates and the calculation of bending of roller are unknown. According to the 2.5-D analytical model, it can be found that, for plates, it is neutral plane offsetting and middle plane elongation or contraction under inner stress that can effectively improve plate shape. Taking double side waves as an example, the appropriate values of bending of roller were obtained by the 2.5-D analytical model related to different initial unevenness, which was applicable to the current on-line adjusting of bending of roller in rolling industry.
基金Project (No. 50575143) supported by the National Natural Science Foundation of China
文摘An adaptive finite element-element-free Galerkin (FE-EFG) coupling method is proposed and developed for the numerical simulation of bulk metal forming processes. This approach is able to adaptively convert distorted FE elements to EFG domain in analysis. A new scheme to implement adaptive conversion and coupling is presented. The coupling method takes both advantages of finite element method (FEM) and meshless methods. It is capable of handling large deformations with no need of remeshing procedures, while it is computationally more efficient than those full meshless methods. The effectiveness of the proposed method is demonstrated with the numerical simulations of the bulk metal forming processes including forging and extrusion.
基金Project (No. 50475020) supported by the National Natural ScienceFoundation of China
文摘The theory of grey systems is a new technique for performing prediction, relational analysis and decision making in many areas. In this paper, the use of grey relational analysis for optimizing the square hole flanging process parameters with considerations of the multiple response (the average flanging height, regular flanging and maximum strain) is introduced. Various flanging parameters, such as the blank inner radius rb, blank inner width B0, are considered. An orthogonal array is used for the experimental design. Multiple response values are obtained using finite element analysis (FEA). Optimal process parameters are determined by the grey relational grade obtained from the grey relational analysis for multi-performance characteristics (flanging height, regular flanging and maximum strain). Analysis of variance (ANOVA) for the grey relational grade is implemented. The results showed good agreement with the experiment result. Grey relational analysis can be applied in multiple response optimi-zation designs.
基金supported by the Scientific Research Foundation for the Returned Overseas Chinese Scholars of Shanxi Province of China (No.9835).
文摘The hot deformation behavior of AA6063 aluminium alloy has been investigated by means of compression tests at temperatures between 400 and 520℃, and strain rates ranging from 2.5 to 10 s^-1. Owing to the barreling, the theoretical model on the basis of Hills general method is used to calculate the flow stress of a cylindrical specimen under uniaxial simple compression so as to consider the friction effect at the die-specimen interface. A method of evaluating the friction coefficient by combining compression tests with the finite element method is presented. The real flow behavior of AA6063 aluminium alloy can be described with sinh-Arrhenius equation. The hot deformation activation energy Q derived from the corrected stress and strain data is 232. 350 kJ/mol.
基金supported by the National Basic Research Program of China (No. 2006CB705401)the National Natural Science Foundation of China (No.51075270)the Natural Science Foundation of the Jiangsu Higher Education Institutions of China (No.10KJD460003)
文摘A modified cellular automata （CA） model of dynamic recrystallization （DRX） and a flow stress-based nucleation parameter identification method have been developed. In the method, the modified CA model, which takes the role of deformation degree on nucleation behavior into consideration, is coupled with an adaptive response surface model （ARSM） to search for the optimum nucleation parameter. The DRX behavior of an oxygen free high conductivity （OFHC） copper with different initial grain sizes has been taken as an example to validate the model. Good agreement is found between the simulated and the experimental results, which demonstrates that the new method can effectively improve the simulation accuracy.
文摘A full distribution CNC system based on SERCOS bus is studied in accordance with the limitations of traditional PC-based motion card. The conventional PC-based motion control card is dispersed into several autonomous intelligent servo-control units with the function of servo driver. The autonomous intelligent servocontrol units realize the loop control of position, velocity and current. Interpolation computation is completed in PC and the computational results are transferred to every autonomous intelligent servo-control unit by high speed SERCOS bus. Software or hardware synchronization technology is used to ensure all servomotors are successive and synchronously running. The communication and synchronization technology of SERCOS are also researched and the autonomous intelligent servo-control card is developed byself. Finally, the experiment of circle contour process on a prototype system proves the feasibility.
基金the National Natural Science Foundation of China (No. 50873060)
文摘An integrated optimization strategy based on Kriging model and multi-objective particle swarm optimization(PSO) algorithm was constructed.As a new surrogate model technology,Kriging model has better fitting precision for nonlinear problem.The Kriging model was adopted to replace computer aided engineering(CAE) simulation as fitness function of multi-objective PSO algorithm,and the computation cost can be reduced greatly.By introducing multi-objective handling mechanism of crowding distance and mutation operator to multiobjective PSO algorithm,the entire Pareto front can be approximated better.It is shown that the multi-objective optimization strategy can get higher solving accuracy and computation efficiency under small sample.
基金sponsored by National Natural Science Foundation of China(50575143)Research Fund for the Doctoral Program of Higher Education(20040248005)
文摘To accurately predict the occurrence of ductile fracture in metal forming processes, the Gurson-Tvergaard （GT） porous material model with optimized adjustment parameters is adopted to analyze the macroscopic stressstrain response, and a practical void nucleation law is proposed with a few material constants for engineering applications. Mechanical and metallographic analyses of uniaxial tension, torsion and upsetting experiments are performed. According to the character of the metal forming processes, the basic mechanisms of ductile fracture are divided into two modes： tension-type mode and shear-type mode. A unified fracture criterion is proposed for wide applicable range, and the comparison of experimental results with numerical analysis results confirms the validity of the newly proposed ductile fracture criterion based on the GT porous material model.
文摘Methods used for digital ship design were studied and formed the basis of a proposed frame model suitable for ship construction modeling. Based on 3-D modeling software, a digital design system for hull structures was developed. Basic software systems for modeling, modifying, and assembly simulation were developed. The system has good compatibility, and models created by it can be saved in different 3-D file formats, and 2D engineering drawings can be output directly. The model can be modified dynamically, overcoming the necessity of repeated modifications during hull structural design. Through operations such as model construction, intervention inspection, and collision detection, problems can be identified and modified during the hull structural design stage. Technologies for centralized control of the system, database management, and 3-D digital design are integrated into this digital model in the preliminary design stage of shipbuilding.
