Optimization of conventional spinning process parameters by means of numerical simulation and statistical analysis

Research in sheet metal spinning has increased due to a greater demand, especially in the transportation industries, for parts with very high strength-to-weight ratios with low cost. Spinning processes are efficient in producing such characteristics and there is great flexibility in the process with a relatively low tool cost. The objectives of this investigation are to define the critical working parameters in spinning, show the effects of these factors on product quality characteristics, and to optimize the working parameters. The example used is the conventional spinning of a cylindrical cup. Optimization of the process is undertaken through the use of statistical analysis tools applied to the data produced from three-dimensional finite element simulations of the process. This has been achieved by generating two ‘designs of experiments’.The first identifies the most critical parameters for product formability and the second shows how these critical parameters affect the product quality. The results show that feed rate,relative clearance, and roller nose radius are the most important working parameters and significantly affect average thickness, thickness variation, and springback of the cylindrical cup. An additional 22 per cent improvement in the product quality characteristic is gained through using the optimum working parameters

Analysis of the forming characteristics for Cu/Al bimetal tubes produced by the spinning process

Tube spinning technology represents a process with high forming precision and good flexibility and is increasingly being used in the manufacture of bimetal composite tubular structures. In the present study, a forming analysis of clad tube and base tube in spinning process was conducted through numerical simulations and experiments. There was an equivalent stress transition on the interface since the stress transmission was retarded from clad tube to base tube. The yield strength became a main consideration during a design bimetal composite tube. Meanwhile, the strain distributions in axial direction, tangential direction, and radial direction were also investigated to determine the deformation characteristics of each component. As the press amount increased, the strain of clad tube changed more than base tube. As the feed rate increased, the strain decreased in axial direction and tangential direction but almost unchanged in radial direction. Simultaneously, a method for controlling the wall thickness of the clad tube and the base tube is proposed. These results to guide the design of bimetal tube composite spinning process have the certain meanings

The FLC, enhanced fromavbility, and incremental sheet forming

The FLC is a well known concept in the sheet metal forming world. It is used to map the material’s formability and the make-ability of a product. The FLC is valid only within certain restrictions. These restrictions are: A: a straight strain path; B: absence of bending; C: absence of through-thickness shear; D: a condition of plane stress.\ud The formability of a material can be increased significantly if one is allowed to violate any of these restrictions, meaning either: use a complex strain path, incorporate bending, incorporate through-thickness shear, or apply a contact stress. Both shear and contact stress change the stress state, and both lower the yield stress in tension and raise the necking limit up to a certain level. Bending creates a non-uniform stress distribution over the thickness of the sheet, resulting in a reduction of the yield force in tension, and it creates a range of stable elongation depending on the sheet thickness at each passage of the punch. The effect of a complex strain path depends on the particular situation; in incremental sheet forming it is based on non-isotropic hardening.\ud In general it will not be possible to create such conditions in the entire product at once. However it is possible to do this intentionally in a small, restricted zone by creating special situations there. By moving this zone over the entire product the whole part can be made with increased formability. This technique of incremental forming is explained briefly. The special conditions around the punch indeed violate the FLC restrictions mentioned above. The enhanced formability obtained in incremental sheet forming is illustrated with many examples

Local Preferences and Place of Death in Regions within England 2010

This report shows public preferences for place of death in the nine English Government Office Regions (GORs), obtained from a population-based telephone survey in 2010. It compares the results with a similar survey carried out in 2003 to understand how preferences are evolving over time. It goes on to contrast these preferences with actual place of death (as reported for that region) in order to shed light on how people's wishes relate to reality and to aid care planning so that preferences are more frequently met

Optimization of Process Parameters in Laser Sheet Metal Bending

Laser sheet metal bending is a die less sheet metal forming process and a non-contact method. It is a thermo mechanical process where by a focussed or partially focused laser beam is used to induce localized heating and consequently deflection of the sheet along the incident beam occurs. The bending occurs because of internal thermal stresses developed as a result of irradiation instead of external forces. It can be very helpful in the process of rapid prototyping of various sheet metal parts because of its process flexibility and ability to design intricate shapes which are the major advantage against conventional methods. In the experiment Nd:YAG laser is used and the work-piece is AISI 304 stainless steel. Various process parameters in the experiment are laser power, scanning speed, beam diameter, pulse duration and number of passes. The effect of each process parameters is observed with respect to total deflection at the free end and bending angle by keeping other parameters constant. Design of experiment (DOE) is done with the help of Taguchi method. The results are analysed graphically and also with the help of ‘Analysis of variance’ and S/N ratios, so as to determine the optimum values of the process parameters and their individual effectiveness towards the net bending effect

Lecture Notes on The Optimal Growth Problem

These notes provide an introduction to the study of optimal growth in the one-sector neoclassical growth model in continuous time. The model is developed using the analogy of Robinson Crusoe living on a deserted island. Both the Hamiltonian method and the phase diagram are presented and explained on an intuitive level. Some familiarity with optimization theory and differential equations, as well as a thorough understanding of intermediatelevel microeconomics, is assumed.Optimal Growth

Influence of processing parameters on forming quality of non-circular spinning

Processing parameters have great influence on forming quality of non-circular spinning. Finite element simulation model of non-circular spinning for the three straight-edge round-corner cross-section (TSRC) hollow-part was established. Variation rules of thickness and springback of TSRC spun workpiece under different processing parameters were obtained by means of orthogonal test as well as the software MSC.MARC. The results show that the influences of the relative clearance ΔC and the feed ratio of roller fz on the maximum wall thickness thinning ratio δt are obvious, and the influences of n and Dr are slight; the influences of the nose radius of roller rρ on the springback angle Δα is the most obvious, and the influences of ΔC and Dr are slight

Outlook Magazine, Autumn 2018

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