Accuracy and precision assesment of stochastic simulation tools for springback variation

The sheet forming industry is plagued by inherent variations in its many input variables, making quality control and improvements a major hurdle. This is particularly poignant for Advanced High Strength Steels (AHSS), which exhibit a large degree of property variability. Current FE-based simulation packages are successful at predicting the manufacturability of a particular sheet metal components, however, due to their numerical deterministic nature are inherently unable to predict the performance of a real-life production process. Though they are now beginning to incorporate the stochastic nature of production in their codes. This work investigates the accuracy and precision of a current stochastic simulation package, AutoForm Sigma v4.1, by developing an experimental data set where all main sources of variation are captured through precise measurements and standard tensile tests. Using a Dual Phase 600Mpa grade steel a series of semi-cylindrical channels are formed at two Blank Holder Pressure levels where the response metric is the variation in springback determined by the flange angle. The process is replicated in AutoForm Sigma and an assessment of accuracy and precision of the predictions are performed. Results indicate a very good correspondence to the experimental trials, with mean springback response predicted to within 1 &deg; of the flange angle and the interquartile spread of results to within 0.22&deg;.<br /

Contact pressure prediction in sheet metal forming using finite element analysis

Tool wear has become a significant issue associated with the forming of high strength sheet steels in the automotive industry. In order to combat this problem, recent research has been devoted to utilizing the contact results obtained from current sheet metal forming software predictions, in order to develop/apply tool wear models or tool material selection criteria for use in the stamping plant. This investigation aims to determine whether a specialized sheet metal forming software package can correctly capture the complex contact conditions that occur during a typical sheet metal stamping process. The contact pressure at the die radius was compared to results obtained using a general-purpose finite element software package, for a simple channel-forming process. Although some qualitative similarities between the two predictions were observed, it was found that significant differences in the magnitude and distribution of the contact pressure exists. The reasons for the discrepancies in results are discussed with respect to the simplifications and assumptions adopted in the finite element model definitions, and with regards to other results available in the literature.<br /

Constitutive modelling of high strength titanium alloy Ti-6Al-4 V for sheet forming applications at room temperature

To enable the design and optimisation of forming processes at room temperature the material behaviour of Ti-6Al-4 V needs to be accurately represented in numerical analysis and this requires an advanced material model. In particular, an accurate representation of the shape and size of the yield locus as well as its evolution during forming is important. In this study a rigorous set of experiments on the quasi-static deformation behaviour of a Ti-6Al-4 V alloy sheet sample at room temperature was conducted for various loading conditions and a constitutive material model developed. To quantify the anisotropy and asymmetry properties, tensile and compression tests were carried out for different specimen orientations. To examine the Bauschinger effect and the transient hardening behaviour in - plane tensile - compression and compression - tensile tests were performed. Balanced biaxial and plane strain tension tests were conducted to construct and validate the yield surface of the Ti-6Al-4 V alloy sheet sample at room temperature. A recently proposed anisotropic elastic-plastic constitutive material model, so-called HAH, was employed to describe the behaviour, in particular for load reversals. The HAH yield surface is composed of a stable component, which includes plastic anisotropy and is distorted by a fluctuating component. The key of the formulation is the use of a suitable yield function that reproduces the experimental observations well for the stable component. Meanwhile, the rapid evolution of the material structure must be captured at the macro - scale level by the fluctuating component embedded in the HAH model. Compared to conventional hardening equations, the proposed model leads to higher accuracy in predicting the Bauschinger effect and the transient hardening behaviour for the Ti-6Al-4 V sheet sample tested at room temperature. (C) 2015 Elsevier Ltd. All rights reserved.1167Ysciescopu

Wear mechanisms in forming of HSS and AHSS

Code : C/64/0

Topological design of cellular structures for maximum shear modulus using homogenization SEMDOT

This paper incorporates the homogenization theory into non-penalized Smooth-Edged Material Distribution for Optimizing Topology (SEMDOT) algorithm to conduct the design of cellular structures with the maximum shear modulus. The parametric study and comparison with existing results obtained by BESO are carried out. The numerical examples in 2D and 3D demonstrate the effectiveness of non-penalized SEMDOT in generating smooth cellular structures with the maximum shear modulus. Compared to BESO, SEMDOT can achieve comparable results and smoother boundaries. Smooth boundaries obtained by SEMDOT can facilitate the manufacturing of obtained cellular structures in 3D or 4D printing

Study on breakdown probability of multi material electrodes in EDM

With the development of EDM technology, some multimaterial electrodes which have some special functions are regularly taking the place of traditional single material electrodes on some machining occasions and becoming widely used. In this paper, the influence of material on discharge breakdown in EDM with multimaterial electrodes is studied. A comparison model about material influence on discharge breakdown under both single discharge condition and continuous discharge condition is established, and the material property factors affecting the probability of discharge breakdown are also analyzed. Finally, a series of experiments are carried out to study the effects of different electrode materials on the discharge breakdown of EDM, a fitting formula of breakdown probability is presented, and the effectiveness of the comparison model is also verified by comparing with experimental results

A model of superoutbursts in binaries of SU UMa type

A new mechanism explaining superoutbursts in binaries of SU UMa type is proposed. In the framework of this mechanism the accretion rate increase leading to the superoutburst is associated with formation of a spiral wave of a new "precessional" type in inner gasdynamically unperturbed parts of the accretion disc. The possibility of existence of this type of waves was suggested in our previous work (astro-ph/0403053). The features of the "precessional" spiral wave allow explaining both the energy release during the outburst and all its observational manifestations. The distinctive characteristic of a superoutburst in a SU UMa type star is the appearance of the superhump on the light curve. The proposed model reproduces well the formation of the superhump as well as its observational features, such as the period that is 3-7% longer than the orbital one and the detectability of superhumps regardless of the binary inclination.Comment: LaTeX, 20 pages, 4 figures, to be published in Astron. Z

RNA and DNA Bacteriophages as Molecular Diagnosis Controls in Clinical Virology: A Comprehensive Study of More than 45,000 Routine PCR Tests

Real-time PCR techniques are now commonly used for the detection of viral genomes in various human specimens and require for validation both external and internal controls (ECs and ICs). In particular, ICs added to clinical samples are necessary to monitor the extraction, reverse transcription, and amplification steps in order to detect false-negative results resulting from PCR-inhibition or errors in the technical procedure. Here, we performed a large scale evaluation of the use of bacteriophages as ICs in routine molecular diagnosis. This allowed to propose simple standardized procedures (i) to design specific ECs for both DNA and RNA viruses and (ii) to use T4 (DNA) or MS2 (RNA) phages as ICs in routine diagnosis. Various technical formats for using phages as ICs were optimised and validated. Subsequently, T4 and MS2 ICs were evaluated in routine real-time PCR or RT-PCR virological diagnostic tests, using a series of 8,950 clinical samples (representing 36 distinct specimen types) sent to our laboratory for the detection of a variety of DNA and RNA viruses. The frequency of inefficient detection of ICs was analyzed according to the nature of the sample. Inhibitors of enzymatic reactions were detected at high frequency in specific sample types such as heparinized blood and bone marrow (>70%), broncho-alveolar liquid (41%) and stools (36%). The use of T4 and MS2 phages as ICs proved to be cost-effective, flexible and adaptable to various technical procedures of real-time PCR detection in virology. It represents a valuable strategy for enhancing the quality of routine molecular diagnosis in laboratories that use in-house designed diagnostic systems, which can conveniently be associated to the use of specific synthetic ECs. The high rate of inhibitors observed in a variety of specimen types should stimulate the elaboration of improved technical protocols for the extraction and amplification of nucleic acids