Dyi g Chen

Study on Wire Rod Drawing Process Using the Rotating Die

This study proposes a cold drawing technology of wire rod with rotating die; it carries out an FEM simulation on rotating drawing using DEFORM-3D commercial software. Frictions among the die and the wire material are assumed as constant shear friction. The effective stress, the effective strain, the velocity field, and the drawing force can be determined from the FEM simulation. In this study, effects of various drawing conditions such as the rotating angular velocity, the half die angle, the frictional factor, the die filet on the drawing forming characteristics are explored effectively. From this FEM simulation, it is noted that the rotating die effect can reduce the drawing force and increase the material flow.

Study of the Titanium Alloy Deformation Behavior in Equal Channel Angular Extrusion

The shear plastic deformation behavior of a material during equal channel angular (ECA) extrusion is governed primarily by the die geometry, the material properties, and the processing conditions. Using commercial DEFORMTM 2D rigid-plastic finite element code, this study investigates the plastic deformation behavior of Ti-6Al-4V titanium alloy during 1- and 2-turn ECA extrusion processing in dies containing right-angle turns. The simulations investigate the distributions of the billet mesh, effective stress and effective strain under various processing conditions. The respective influences of the channel curvatures in the inner and outer regions of the channel corner are systematically examined. The numerical results provide valuable insights into the shear plastic deformation behavior of Ti-6Al-4V titanium alloy during ECA extrusion.

An Investigation into Optimized Ti-6Al-4V Titanium Alloy Equal Channel Angular Extrusion Process

The shear plastic deformation behavior of a material during equal channel angular (ECA) extrusion is governed primarily by the die geometry, the material properties, and the process conditions. This paper employs the rigid-plastic finite element (FE) to investigate the plastic deformation behavior of Ti-6Al-4V titanium alloy during ECA extrusion processing. Under various ECA extrusion conditions, the FE analysis investigates the damage factor distribution, the effective stress-strain distribution, and the die load at the exit. The relative influences of the internal angle between the two die channels, the friction factors, the titanium alloy temperature and the strain rate of billet are systematically examined. In addition, the Taguchi method is employed to optimize the ECA process parameters. The simulation results confirm the effectiveness of this robust design methodology in optimizing the ECA processing of the current Ti-6Al-4V titanium alloy.

Robust Design of Ring Rolling Process for Titanium Alloy Using the Taguchi Method and the Finite Element Method

To obtain the required plastic strain and desired tolerance values in the ring rolling process, it is necessary to control many factors. Major factors include the mandrel width, the rotation speed of driver roll, the feed ratio of mandrel, and the workpiece temperature. This study uses rigid-plastic finite element (FE) software to investigate the plastic deformation behavior of a titanium alloy (Ti-6Al-4V) workpiece under ring rolling. This study analyzes the damage factor distribution, the effective strain, the effective stress and the die radius load in the workpiece under various ring rolling conditions. We used the Taguchi method to determine the optimum design parameters. Results confirm the suitability of the proposed design process, which allows a ring rolling die to achieve a perfect design during finite element method.

Finite Element Simulations of A1100 / A3003 (A6063) Sandwich Sheet Rolling Processing

This study performs DEFORMTM 3D three-dimensional finite element simulations to analyze the plastic deformation of A1100 / A3003 sandwich sheets during rolling. The finite element code is based on a rigid-plastic model, and the simulations in this study assume that the rollers are rigid bodies and that the deformation-induced change in temperature during rolling is negligible. The rolled product comprises a central sheet of A1100 aluminum alloy sandwiched between upper and lower sheets of either A3003 or A6063 aluminum alloy. The simulations examine the effects of sheet thickness and reduction ratio on the maximum effective stress, maximum effective strain, Y-direction load, and maximum damage induced within the rolled product. This study also compares the simulation results for the final thicknesses of the three layers in the rolled A1100 / A3003 (A6063) sandwich sheet with experimental measurements and bonding conditions.

Rigid-Plastic Finite Element Simulation of Deformation Mechanisms during Rolling of Complex Sheets Containing an Inclusion

Using rigid-plastic finite element DEFORMTM 2D software, this study simulates the plastic deformation of complex sheets at the roll gap during the sheet rolling process. Specifically, the study addresses the deformation of complex sheets containing inclusion defects. Under various rolling conditions, the present numerical analysis investigates the damage factor distributions, the void length at the front and rear of the inclusion, the deformation mechanisms, and the stress-strain distributions around the inclusion. The relative influences of the thickness reduction, the roll radii, and the friction factors on the void length at the front and rear of the inclusion, respectively, are systematically examined. Additionally, the correlation between the front and rear void lengths and a series of damage factors is explored. The simulation results appear to verify the suitability of the DEFORMTM 2D software for modeling the rolling of complex sheets containing inclusions.

Optimum Design of Si-Cr Alloy Springs for Seismic Vibration Isolator

In this paper, a dynamic stress analysis of seismic vibration isolator was carried out by using ANSYS. The vibration isolator consisted of Si-Cr springs and magnetorheological dampers. The stress and deformation of the springs were calculated when an impact load was applied to the isolator. From the simulation for six different springs, in terms of their wire dimeter and coil diameter, an optimum shape of the springs to minimize the stress and deformation was determined.

Study of 6061 Aluminum Alloy Milling Using Four-Blade Face Cutter

In this paper, construction of finite element analysis based on DEFORMTM 3D four-blade face milling cutter aluminum 6061 cutting, explore the finite element analysis of face milling cutter rotating in a circle cutting of aluminum alloy 6061.Tool types used WC milling cutters, cutting speed, feed rate as fixed process parameters. The study analyzed four rotations of the blade face milling chip formation, effective stress, effective strain and material changes in temperature and tool wear.

Study of CIGS Thin Films Solar Cell P2 Layer Scribing Using UV Laser

This study will be UV (355nm) laser processing system as a carrier. Using laser direct forming for CIGS solar cell technology P2 layer of stainless steel studied electrode insulated characteristic. To explore the impact of this process on the way to a stainless steel substrate P2 film sizes using its laser different frequency parameters. The experimental results indicated that the electrode pattern of the experiment was similar to that of the simulation result, and the laser process has good results in scribing processing. The analysis results confirm the effectiveness of the laser apparatus when applied to a CIGS solar cell P2 layer of stainless steel.

Investigation into Bicycle Front Fork Forming Process of Simulation and Experiment

This study uses the three dimensional finite element code to examine the plastic deformation behavior of bicycle front fork forging. First the paper used Solid works 2010 3D graphics software to design the bicycle front fork die, and that used rigid-plastic model finite element analytical methods, and assuming mode to be rigid body. The front fork material is titanium alloy Ti-6Al-4V. A series of simulation analyses in which the variables depend on die temperature, billet temperature, forging speed, friction factors, die angle are reveal to effective stress, effective strain, die radial load distribution and damage value for bicycle front fork forming. The simulation combined Taguchi method to analysis optimization. The results of the analysis can be used to stabilize finite element software to forming front fork, and also confirm the suitability of bicycle front fork through experiment optimization.