A Study For Efficiently Solving Optimisation Problems With An Increasing Number Of Design Variables

Coupling optimisation algorithms to Finite Element Methods (FEM) is a very promising way to achieve optimal metal forming processes. However, many optimisation algorithms exist and it is not clear which of these algorithms to use. This paper investigates the sensitivity of a Sequential Approximate Optimisation algorithm (SAO) proposed in [1-4] to an increasing number of design variables and compares it with two other algorithms: an Evolutionary Strategy (ES) and an Evolutionary version of the SAO (ESAO). In addition, it observes the influence of different Designs Of Experiments used with the SAO. It is concluded that the SAO is very capable and efficient and its combination with an ES is not beneficial. Moreover, the use of SAO with Fractional Factorial Design is the most efficient method, rather than Full Factorial Design as proposed in [1-4]

Ultrasonic roll bite measurements in cold rolling: Contact length and strip thickness

In cold rolling of thin metal strip, contact conditions between the work rolls and the strip are of great importance: roll deformations and their effect on strip thickness variation may lead to strip flatness defects and thickness inhomogeneity. To control the process, online process measurements are usually carried out; such as the rolling load, forward slip and strip tensions at each stand. Shape defects of the strip are usually evaluated after the last stand of a rolling mill thanks to a flatness measuring roll. However, none of these measurements is made within the roll bite itself due to the harsh conditions taking place in that area. This paper presents a sensor capable of monitoring strip thickness variations as well as roll bite length in situ and in real time. The sensor emits ultrasonic pulses that reflect from the interface between the roll and the strip. Both the time-of-flight of the pulses and the reflection coefficient (the ratio of the amplitude of the reflected signal to that of the incident signal) are recorded. The sensor system was incorporated into a work roll and tested on a pilot rolling mill. Measurements were taken as steel strips were rolled under several lubrication conditions. Strip thickness variation and roll-bite length obtained from the experimental data agree well with numerical results computed with a cold rolling model in the mixed lubrication regime

Prediction of the mechanical response of canine humerus to three-point bending using subject-specific finite element modelling

Subject-specific finite element models could improve decision making in canine long-bone fracture repair. However, it preliminary requires that finite element models predicting the mechanical response of canine long bone are proposed and validated. We present here a combined experimental–numerical approach to test the ability of subject-specific finite element models to predict the bending response of seven pairs of canine humeri directly from medical images. Our results show that bending stiffness and yield load are predicted with a mean absolute error of 10.1% (±5.2%) for the 14 samples. This study constitutes a basis for the forthcoming optimization of canine long-bone fracture repair

Numerical modelling of micro-plasto-hydrodynamic lubrication in plane strip drawing

peer reviewedThis paper presents a new finite element model capable of predicting the onset of micro-plasto-hydrodynamic (MPH) lubrication and the amount of lubricant escaping from surface pockets in metal forming. The present approach is divided in two steps. First, a simulation at the macroscopic level is conducted. Then, a second simulation highlighting microscopic liquid lubrication mechanisms is achieved using boundary conditions provided by the first model. These fluid-structure interaction computations are made possible through the use of the Arbitrary Lagrangian Eulerian (ALE) formalism. The developed methodology is validated by comparison to experimental measurements conducted in plane strip drawing. The effect of physical parameters like the drawing speed, the die angle and the strip thickness reduction is investigated. The numerical results show good agreement with experiments

Mesh management methods in finite element simulations of orthodontic tooth movement

In finite element simulations of orthodontic tooth movement, one of the challenges is to represent long term tooth movement. Large deformation of the periodontal ligament and large tooth displacement due to bone remodelling lead to large distortions of the finite element mesh when a Lagrangian formalism is used. We propose in this work to use an Arbitrary Lagrangian Eulerian (ALE) formalism to delay remeshing operations. A large tooth displacement is obtained including effect of remodelling without the need of remeshing steps but keeping a good-quality mesh. Very large deformations in soft tissues such as the periodontal ligament is obtained using a combination of the ALE formalism used continuously and a remeshing algorithm used when needed. This work demonstrates that the ALE formalism is a very efficient way to delay remeshing operations

A thermo-elasto-viscoplastic constitutive model for residual stresses in FSW

ABSTRACT This work deals with the prediction of the residual stresses in the Friction Stir Welding (FSW) process. The FSW process is a relatively recent welding process. FSW is a solid-state joining process during which materials are not melted. Thus, the heat-affected zone is smaller and the quality of the welding is better with respect to more classical welding processes. In spite of the important number of applications of the FSW, the phenomena happening during the welding are still not well understood. Therefore, the investigations on this process and especially regarding numerical simulations are still very active The mechanical properties of the weld in service crucially depend on the residual stress field. To accurately predict this residual stress field, a thermo-elasto-viscoplastic constitutive model is used in the simulations for the material plates. This constitutive model is used both during FSW process, as well as during the cooling phase