0000000000285980
AUTHOR
N. Alberti
Analisi della distribuzione di tensioni sulla sezione contratta di provini cilindrici di trazione
Molti Autori si sono occupati della determinazione della distribuzione di tensioni sulla sezione contratta dei provini cilindrici di trazione sin da quando il Ludwik [1] mostro che la rottura si inizia in corrispondenza dell’asse, ove pertanto dovrebbero manifestarsi le condizioni di sollecitazione piu gravose.
Computer-Aided Simulation of Die Filling Processes
Summary A numerical method for analysing the filling of axisymmetrical dies of complex shape is proposed. The method, which is a further development of a LP finite element model, is able to take into account the contact conditions directly in the mathematical formulation of the problem. In such a way the solution of the die filling process is obtained by solving a LP problem, avoiding problems of numerical convergence and the heavier calculations requested by other iterative methods.
Interdependence Between Tool Fracture and Wear
Wear and fracture are the main causes of tool scrapping. However fracture plays a major role for increasing values of the hardness and brittleness of tool materials or when low-cobalt tungsten carbides are used or in interrupted cutting conditions where it is the most relevant factor for tool scrapping. In order to obtain the optimal values of the cutting speed both these factors should be considered. The hypothesis of stochastic independence among them simplifies the mathematical formulation of the optimization problem; but experimental investigations do not agree with this assumption and, as a matter of fact, the probability density function of tool fracture results to be dependent on the…
Springback evaluation in fully 3-D sheet metal forming processes
Abstract In the modern manufacturing industries the knowledge and proper control of the sheet metal springback after forming is a fundamental aspect in the achievement of near net shape stamped parts. In this paper an effective springback prediction in some fully three-dimensional stamping processes is carried out. Such a prediction is based on a combined approach in which an explicit finite element code has been employed to simulate the forming phase while a traditional implicit procedure has been used to analyse the springback phase. The results obtained have been compared with a set of experimental tests and an excellent correlation between the predicted and experimental data has been fo…
A New Numerical Method for Axisymmetrical Forming Processes
Summary In this paper a numerical method for the analysis of axisymmetrical forming processes is proposed. This method represents the last development of a previous one which allows to solve forming problems in plane strain condition. The proposed model is baaed on the finite element discretization and on the linearization of the yield surface which leads to solve a LP problem. Two different examples of application, concerning the upsetting of a cylinder and of a hollow disk are reported.
Prediction of Ductile Fractures in Metal-Forming Processes: an Approach Based on the Damage Mechanics
The Authors propose a new approach for the prediction of ductile fractures in bulk metal forming processes: the approach is based on a numerical analysis able to take into account damage occurrence and evolution in constitutive equations. The model supplies the distribution of the void volume fraction in the workpiece during the deformation path: consequently, the comparison to a critical value, determined by means of a simple tension test, allows to predict the growth of defects. The proposed approach has been applied to the drawing process: the numerical results have been compared with a set of experimental tests showing a good predictive capability of the model.
Sheet metal forming of titanium blanks using flexible media
Abstract Sheet metal forming processes using flexible media are increasingly utilized in the industrial practice due to the relatively low tooling cost. In the present investigation, a rubber forming process is applied to the manufacturing cycle of a titanium alloy component for acoustic tweeters. The proposed process allows a reduction in manufacturing costs and production time since it permits the elimination of some joining operations. The FEM analysis has permitted the definition of the optimal process parameters and tooling geometry. Accordingly, several components have been produced; the achieved quality level is comparable with the one obtained utilizing the conventional technology a…
Some observations on metal cutting with reference to the mechanical characteristics of working materials
The hypothesis of the minimum work of Merchant is applied to materials with different yield points in traction and in simple compression on the assumption that these materials yield in accordance with the paraboloid yield-criterion. The experimental data obtained from cutting tests like those described in this paper may apparently be in good agreement with theoretical results. But closer examination reveals that the values of the shear angle φ depend largely on the cutting speed and on the feed p. r. All relationship between φ and (λ — γ) (difference between the friction angle on the rake face and the rake angle) must therefore take in account the influence of the above variables.
Analysis of metal spinning processes by the ADINA code
Abstract The ADINA code, version 84, has been employed for the analysis of sheet spinning processes. The main process parameters have been evaluated in different working conditions; namely for various geometries and constitutive laws of the material.
Analysis of Some Innovative and Flexible Sheet Forming Processes
In the field of sheet forming, innovative and flexible processes that do not impose the use of expensive conventional equipments and/or do not require time consuming set-up operations have become, nowadays, a rather promising research topic. Two different main lines are currently followed: the former is based on the development of new stamping processes based on the utilization of flexible media, while the latter is aimed to develop so called progressive forming processes (spinning and incremental forming). Both hydro-forming and incremental forming permit a very relevant reduction of the tooling and set-up costs and improve process flexibility. These items are discussed in detail in the pa…
A Numerical Method for the Analysis of Plane-Strain Forming Processes with Unilateral Constraints
The Authors propose a numerical model for the solution of plane-strain forming processes, based on the linearization of the yield surface. This allows to employ the linear programming technique for the solution of the variational problem derived from the application of the upper-bound theorem. Such a model permits to take into account the unilateral constraints in a very simple way. Therefore it is well suited to solve a large class of problems, such as sheet forming, in which the unilateral constraints are often present.
Forming Processes Design Oriented to Prevent Ductile Fractures
During cold forming processes ductile fractures are sometimes encountered, depending on the operating parameters and on the material properties and determining the production of defective components to be discarded; for this reason the development of a general approach for the prediction of this type of defects is particularly suitable and this aim has been pursued by a large number of researchers in the last two decades. In the paper the most important and diffused models are described and analysed in order to outline the advantages offered by each of them. Some applications to typical metal forming processes are presented, carrying out a comparison between the numerical predictions and th…
Prediction of Ductile Fractures Occurrence in Deep Drawing of Square Boxes
Abstract The authors propose a new approach for the prediction of tearing in the deep drawing process of square boxes. Such an approach is based on a damage mechanics formulation and in particular on the yield condition for damaging materials proposed by Tvergaard and Needleman and on a strain controlled nucleation model. The flow rule associated to the yield condition is introduced in a finite element explicit formulation founded on the solution of the dynamic equilibrium equation and on an explicit time integration scheme. By this way the developed model allows to calculate the void volume fraction value during the deep drawing process of square boxes and consequently to predict the insur…
Recent Developments in the Design and Control of Cold Forming Processes
In the paper some problems of process design and control in metal forming are taken into account. In particular as far as the former aspect is concerned, the problem of the preform design in cold forging is analyzed: the contributions offered by several researchers are presented and an innovative design procedure is proposed. As well, the suitability of closed-loop control systems for metal forming applications is discussed with particular reference to sheet stamping operations; again, after an overview of the state of the art, the advantages offered by the application in this field of Artificial Intelligence techiniques is pointed out.
Friction stir welding: a solid state joining process
A wide experimental investigation on the friction stir welding of AA6082-T6 sheets is presented. In particular the influence of some of the most relevant process parameters was taken into account, with the aim to maximize the joint strength; furthermore the joint fatigue behavior was considered too. An accurate analysis on the obtained parts was carried out, with particular attention to the material microstructure evolution. The obtained results permitted to develop a proper FSW process engineering.
Cost Analysis of FMS Throughput
Abstract The need for an effective cost planning and control system is stressed in today highly competitive manufacturing environment. The conventional approaches of machining economics to cost analysis are no more able to cope with the new structure of the production costs in the highly automated - highly integrated manufacturing systems. Suitable cost analysis procedures should provide a strong integration between process planning data and overall system performances. The here proposed procedure for the estimate of the unit manufacturing cost in FMSs achieves this integration by using performance evaluation techniques like discrete event simulation or queueing network models.
Knowledge-Based Systems and F.E. Simulations in Metal-Forming Processes Design An integrated Approach
Summary The automatic computer aided planning and design of cold forming processes includes several phases, among which the most important are the optimal choice of the forming operations sequence and, for each operation, the determination of the more suitable operating parameters. With this aim the Authors propose an integrated approach based on the preliminary choice of some feasible forming sequences, carried out by means of a knowledge-based system, and on the subsequent determination of the optimal one employing a finite element simulation of the process.
Innovative sheet metal forming processes: numerical simulations and experimental tests
Abstract In this paper, computer aided engineering of some innovative sheet metal forming processes is reviewed. In particular, tube hydroforming processes and spinning processes are examined. Advanced numerical tools are utilized with the aim to design proper forming operations able to produce sound components. Furthermore, as far as the spinning process is concerned, experimental verifications are carried out to confirm the effectiveness of the numerical predictions.
An Explicit Model for the Thermal-Mechanical Analysis of Hot Metal Forming Processes
Abstract In the paper the authors propose a new finite element code for the coupled thermal-mechanical analysis of hot metal forming processes. As regards the mechanical problem, an explicit algorithm based on the solution of the dynamic equilibrium equation and an explicit time integration scheme is used, while the heat transfer analysis is based on the solution of the thermal equilibrium equations; in order to put the thermal problem in an explicit linear form a three level scheme has been employed for the discretization of the time variable. The model is based on a staggered procedure, in which the mechanical and the thermal analysis are carried out with respect to different time horizon…
Central Bursting Defects in Drawing and Extrusion: Numerical and Ultrasonic Evaluation
Abstract A new approach for the prediction of central bursting defects in extrusion and drawing is proposed: a finite element analysis of the processes has been carried out, and the obtained results have been elaborated by means of a post-processor, which, employing a proper ductile fracture criterion, is able to suggest if and where the central burst occur. An ultrasonic control system able to detect the insurgence of defects with a resolution of 0.2 mm. has been setup in order to verify the predictive capability of the model. The experimental results show a good agreement with the numerical predictions confirming the effectiveness of the proposed approach, whose industrial application app…