基于Ayada损伤模型的板料冲裁过程数值模拟

使用DEFORM-2D软件对AISI-1045钢的冲裁工艺过程进行弹塑性大变形有限元数值模拟,采用Ayada断裂准则,预测了材料变形过程中静水应力、等效应力和等效应变的分布以及发展趋势、冲裁最后阶段微裂纹产生发展和最终断裂,模拟结果中的材料断裂和冲裁力的变化与实验结果一致.     

Prediction of optimum clearance in sheet metal blanking processes

The blanking process and structure of the blanked surface are influenced by both the tooling (clearance and tool geometry) and properties of the workpiece material (blank thickness, mechanical properties, microstructure, etc.). Therefore, for a given material, the clearance and tool geometry are the most important parameters. The objective of the present work is to develop a methodology to obtain the optimum punch-die clearance for a given sheet material by simulation of the blanking process. A damage model of the Lemaitre type is used in order to describe crack initiation and propagation into the sheet. A comparative study between numerical and experimental results shows good agreement.     

Fracture limit prediction using ductile fracture criteria for forming of an automotive aluminum sheet

Forming limit curves at neck and at fracture have been experimentally determined, and surfaces of fractured dome specimens have been observed optically and in the SEM, for an automotive AA6111-T4 sheet material. Various continuum ductile fracture criteria from the literature along with the assumptions of power law hardening, Hill’s quadratic yield criterion, and proportionality of stress and strain paths have been utilized for prediction of forming limit curve at fracture and compared with the experimental curve to assess the applicability of the different fracture criteria. The maximum shear stress criterion by Tresca predicts reasonably well the fracture limits of AA6111-T4 sheet material for a range of strain ratios, and is consistent with the microstructural observations. The criterion can be used to predict fracture limit curves from uniaxial tensile data and plane strain limit at fracture. A methodology for incorporating such a ductile fracture criterion into FE simulations of sheet stampings for prediction of fracture is discussed.     

Matrix-presentation linear least square error method of inverse elastic-plastic large deformation finite element model for upsetting

The main purpose of this paper is to develop the matrix presentation linear least square error method of inverse elastic-plastic large deformation finite element model for upsetting to obtain the friction coefficients during the upsetting process. This inverse model assumed the linear material and based on the modified experimental loading increments using the linear modified experimental upsetting loading standard proposed in this paper. Then the friction coefficients of contact boundary between the workpiece and the die at specific finite element analysis stages can be derived. Finally, using the cubic spline fitting, the history of friction coefficient during the upsetting process can be obtained. It is demonstrated that the workpiece profile of upsetting experiment is quite identical to the workpiece profile of simulation using the result obtained in this paper as the history of friction coefficient of contact boundary, and furthermore the distribution of stress and strain of the workpiece during upsetting process can be understood.     

A new thermal property measurement technique by modified pattern search method

The high temperature thermal properties of materials are critical in industrial production and theoretic simulation. However, these properties are not always readily available. In this paper, a new technique was developed to obtain the temperature dependent thermal conductivity and specific heat through only one experiment. More importantly, this experiment was very convenient, since only thermal cycle recording was necessary. In addition, the finite element method and pattern search method were applied to optimize the supposed thermal property values. In order to avoid the convergence difficulty of the classical pattern search method, the step size adjusting function was rewritten. A solid sample and a particle like sample were selected to verify the measurement technique. The verification experiment showed that the thermal property results were accurate to some extent.     

An identification method for joint structural parameters using an FRF-based substructuring method and an optimization technique

A new method is proposed to identify the joint structural parameters of complex systems using a frequency response function (FRF)-based substructuring method and an optimization technique. The FRF method is used to estimate the joint parameters indirectly by minimizing the difference between the reference and calculated responses using a gradient-based optimization technique with analytical gradient information. To assess the robustness of the identification method with respect to noisy input data, FRFs contaminated by uniformly distributed random noise were tested in a numerical example. The effects of the random noise and the magnitude of the connection stiffness values on the accuracy of the method were investigated while identifying the joint parameters. When the FRFs were contaminated with random noise, the proposed procedure performed well when used to identify the stiffness values, but the accuracy of identification is deteriorative when used to identify the damping coefficients. The joint parameters of a real bolted structure were also identified by the proposed method. The results show that it can be applied successfully to real structures, and that a hybrid approach using both calculated and measured FRFs in the substructure model can enhance the quality of the identification results.     

基于CAE技术的优化方法及其应用

讨论了基于CAE技术的优化方法及其工程实现方法。基于ANSYS的CAE分析对悬臂梁的截面形状进行优化的实例表明,基于CAE技术的优化方法能更加细致地对工程问题进行分析优化,可以同时得到优化方案以及与之对应的物理场分析结果。     

Improvement of substructuring reduction technique for large eigenproblems using an efficient dynamic condensation method

An accelerated substructuring reduction procedure for the iterated improved reduced system (IIRS) method is proposed. The iterated IIRS method can be combined with a substructuring scheme to provide an efficient methodology for large-scale eigenvalue problems. Not only can it reduce eigenvalue analysis errors through successive iterations, but the accuracy of the eigenanalysis is not sensitive to the selected master degrees of freedom. In practical structural eigenproblems, reducing the number of iterations can save a great deal of computation cost. The present substructuring technique modifies the iterative form of the transformation matrices in each substructure to achieve faster convergence. Applications of the present method to two numerical examples demonstrate that the proposed method can obtain lower eigensolutions of structures more accurately and efficiently, as compared with those of the current substructuring technique.     

Fast thickness prediction and blank design in sheet metal forming based on an enhanced inverse analysis method

In sheet metal forming process, inverse analysis codes serve a useful purpose at the early product design stage when an approximate analysis is required to determine if the initial concept part can be made and where the failures and defects will occur. In this paper, a robust energy-based 3D mesh mapping algorithm is used to obtain the initial solution and is followed by a reverse deformation method to improve its accuracy. The novel initial solution scheme can consider the material and the process parameters, and thus lead to fewer Newton–Raphson iterations. The actions of the punch, die, blank holder and the drawbead are fully considered. A fast and reliable boundary condition treatment method is implemented to workpiece without binder and addendum information. Contact treatment between punch and die is an essential issue which greatly affects the convergence of Newton–Raphson iterations. A reliable contact treatment based on topological relations of workpiece is proposed to define the force direction between die and punch. Equivalent drawbead forces are also considered with a simplified model. With the improved aspects, the in-house inverse analysis code InverStamp is developed. Application to a square box and a clover-shaped cup are presented with demonstrations of the validity of the code and the efficiency of the proposed modified approaches.     

某型磁悬浮列车结构动力学有限元数值计算及优化分析

对某型磁悬浮列车的结构动力学特性进行了有限元数值计算,获得了列车结构体的动力学基本品质特性,即固有频率与振动模态.在此数值分析工作基础上,研究分析了车体结构的低频敏感部位与非敏感变量,由此建立了车体结构的优化数学模型,通过数值优化分析计算,在车体底盘梁式构件减重20%的条件下以及在车厢梁式构件减重10%的条件下,结构体固有频率特性没有明显改变,达到了保持结构基本动力学品质指标,而结构有一定幅度减重的工作目的.     

Prediction of Deformed Configuration and Ductile Fracture for Simple Upsetting Using an Artificial Neural Network

This paper suggests a scheme for simultaneously accomplishing the prediction of fracture initiation and geometrical configuration of deformation in metal forming processes using an artificial neural network. A three-layer neural network is used and a back-propagation algorithm is adapted to train the network. The Cockcroft–Latham criterion is used to estimate whether fracture occurs during the deformation process. The geometrical configuration and the value of ductile fracture are measured by the finite-element method. The predictions of the neural network and the numerical results of simple upsetting are compared. The proposed scheme has predicted the geometrical configuration and fracture initiation successfully.     

Cost optimization of submersible motors using a genetic algorithm and a finite element method

This paper presents an optimal design method to optimize cost of three-phase submersible motors. The optimally designed motor is compared with an industrial motor having the same ratings. The motor design procedure consists of a system of non-linear equations, which imposes induction motor characteristics, motor performance, magnetic stresses, and thermal limits. The genetic algorithm (GA) is used for cost optimization, and a software algorithm has been developed. As a result of the realized optimization, besides the improvements on the motor cost, motor torque improvements have also been acquired. The 2-D finite element method (FEM) is then used to confirm the validity of the optimal design. Computer simulation results are given to show the effectiveness of the proposed design process that can achieve a good prediction of the motor performance. Through the studies accomplished, it has been observed that submersible induction motors’ torques and efficiencies improve, their length reduces, and hence some material savings are obtained.     

2-D discontinuous chip cutting model by using strain energy density theory and elastic-plastic finite element method

The formation of discontinuous chip is investigated in this paper. The cutting simulation was conducted on 60–40 brass (60% Cu, 40% Zn) under an extremely low cutting speed. The region of the maximum strain energy density (SED) distribution value relative to the minimum value, i.e. (dw/dv)_min^max, was used as the criterion to predict the initial breakage location under the presumption that the curvature direction of the maximum SED was the direction of crack growth. The shape and cutting force of discontinuous chip crack, the stress and strain distribution of the workpiece and chip, and the variation of various nodal force on the chip–tool interface were derived.     

Optimum design of structures with stress and displacement constraints using the force method

A new structural analysis and optimization algorithm is developed to determine the minimum weight of structures with the truss and beam-type members under displacement and stress constraints. The algorithm combines the mathematical programming based on the sequential quadratic programming (SQP) technique and the finite element technique based on the integrated force method. The equilibrium matrix is generated automatically through the finite element analysis while the compatibility matrix is obtained directly using the displacement–deformation relations and the single value decomposition (SVD) technique. By combining the equilibrium and compatibility matrices with the force–displacement relations, the equations of equilibrium with the element forces as variables are obtained. The proposed method is extremely efficient to analyze and optimize the truss and beam structures under stress and displacement constraints. The computational effort required by the force method is found to be significantly lower than that of the displacement method. The effect of the geometric nonlinearity in the structural optimization problems under the stress and displacement constraints were also investigated and it is illustrated that the geometric nonlinearity is not an important issue in these types of problems and hence, it does not affect the final optimum solution significantly. Four examples illustrate the procedure and allow the results to be compared with those reported in the literatures.     

Design and testing of an external drag balance for a hypersonic shock tunnel

An external force balance for a hypersonic shock tunnel was developed. The design utilized finite element analysis that identified the dynamics of the balance. A simulated impulse and a step load were applied to the design, the former for determining the simulated transfer function and the latter to validate the design. The numerical modeling showed the feasibility of this approach for designing stress wave force balances. A force balance based on the design was fabricated, calibrated statically and dynamically, and implemented in a shock tunnel for measuring drag of a blunt cone at Mach 9.4. The measured drag compared well with modified Newtonian theory.     

Nonlinear transient response analysis for double walls with a porous material supported by nonlinear springs using FEM and MSKE method

In this paper, we newly propose a fast computation method for the nonlinear transient responses including coupling between nonlinear springs and sound proof structures having porous materials using FEM. In this method, we extend our numerical method named as Modal Strain and Kinetic Method (i.e. MSKE method proposed previously by Yamaguchi who is one of the authors) from linear damping analysis to nonlinear dynamic analysis. We assume that the restoring force of the spring has cubic nonlinearity and linear hysteresis damping. To calculate damping properties for soundproof structures including elastic body, viscoelastic body and porous body, displacement vectors as common unknown variable are solved under coupled condition. The damped sound fields in the porous materials are defined by complex effective density and complex bulk modulus. The discrete equations in physical coordinate for this system are transformed into nonlinear ordinary coupled differential equations using normal coordinates corresponding to linear natural modes. Further, using MSKE method, modal damping can be derived approximately under coupled conditions between hysteresis damping of viscoelastic materials, damping of the springs and damping due to flow resistance in porous materials. The modal damping is used for the nonlinear differential equation to compute nonlinear transient responses.Moreover, using the proposed method, we demonstrate new vibration phenomena including nonlinear coupling between nonlinear springs and soundproof structures by use of a simplified model. As a typical numerical example of the soundproof structure, we adopt double walls with a porous material. The double walls are supported by nonlinear concentrated springs. We clarify influences of amplitude of the impact force on nonlinear transient responses. We focused on the vibration modes, which magnify the amplitudes of the double walls. In these modes, the internal air of the porous material played a role of a pneumatic spring. Under a very large impact force as a severe condition, there exist the complicated nonlinear couplings between these modes and the super harmonic components of the rigid modes of the whole structure with large deformations in the nonlinear springs.     

Tailored blank design and prediction of weld line movement using the backward tracing scheme of finite element method

To achieve weight and cost reductions in component manufacturing, tailored blank is introduced for forming automotive structural skin components. In order to obtain successful application of tailored blanks without necessarily trimming after the forming process, it is critical to design an initial welded blank and to predict the weld line movement, which is usually determined by intuition and experience with the trial-and-error approach. A systematic approach method of the backward tracing scheme, which is confirmed by experiment, is extended to design the initial tailored blank for net-shape production in this study. The optimised tailored blank by the backward tracing scheme appears to be successful in obtaining a net-shape stamping product. This blank also improves the forming condition during stamping process. All simulation results show that the backward tracing scheme can be applied to more general blank design.     

Static electromechanical response of smart composite/sandwich plates using an efficient finite element with physical and electric nodes

An efficient quadrilateral element, recently developed by the authors, based on an improved zigzag theory is assessed for the static electromechanical response of hybrid plates with electroded piezoelectric sensors and actuators. The theory accounts for the transverse normal strain due to the electric field in the approximation of deflection. The electric potential is approximated as layerwise quadratic across the thickness. By introducing an electric node in the element for the electric potentials of the electroded piezoelectric surfaces, the equipotential condition of such surfaces is modelled very efficiently. The electric potential degrees of freedom (DOF) corresponding to the quadratic component of the electric potential distribution are associated with the four physical nodes to allow for the inplane electric field induced due to direct piezoelectric effect. The requirement of C¹ continuity of interpolation functions of the deflection is circumvented by employing the improved discrete Kirchhoff constraint technique. The finite element (FE) formulation is validated by comparing the results with other available results in the literature. Comparison of the present results for static response of a variety of piezoelectric bimorph, hybrid composite and sandwich plates, with 3D analytical and FE solutions and those of other available elements establishes that the present element is accurate, robust and computationally efficient.     

Determination of NSIFs and coefficients of higher order terms for sharp notches using finite element method

An overdeterministic method was used for calculating the Notch Stress Intensity Factors (NSIFs) as well as the coefficients of the higher order terms for structures containing sharp notches. The series solution of displacement fields around the notch tip was fitted to a large number of nodal displacements obtained from finite element analysis. An over-determined set of simultaneous linear equations was then derived and the nodal displacements reduced to a small set of unknown coefficients by employing the concept of the least-squares method. The efficiency of the proposed method was assessed through analyzing several notched specimens under pure mode I, pure mode II and mixed modes I/II loading. The accuracy of the NSIFs and the coefficients of higher order terms was evaluated by comparing them with the results available in the literature, or the results obtained by the boundary collocation method. While the presented method is simple, it yields very good results.