Thermal Analysis of Bending Under Tension Test

AbstractThe tribological conditions in deep drawing can be simulated in the Bending Under Tension test to evaluate the performance of new lubricants, tool materials, etc. Deep drawing production with automatic handling runs normally at high rate. This implies considerable heating of the tools, which sometimes can cause lubricant film breakdown and galling. In order to replicate the production conditions in bending under tension testing it is thus important to control the tool/workpiece interface temperature. This can be done by pre-heating the tool, but it is essential that the interface temperature during testing is similar to the one in the production tool. A universal sheet tribo-tester has been developed, which can run multiple tests automatically from coil. This allows emulating the temperature increase as in production. The present work performs finite element analysis of the evolution and distribution of temperature in the bending under tension test by making use of boundary conditions and calibration values directly measured from experiments. The overall methodology combines 2D and 3D models of the bending under tension test with steady state and transient thermal and thermo-mechanical procedures. Results show that the proposed methodology applied to a single stroke can effectively and accurately predict the interface temperature in the test tool, thus avoiding the otherwise required thousands of thermo-mechanical FEM analyses of temperature development during testing before thermal steady state has been reached

Numerical and experimental analysis of resistance projection welding of square nuts to sheets

Projection welding of nuts to sheets is a widely utilized manufacturing process in the automotive industry. The process entails challenges due the necessity of joining different sheet thicknesses and nut sizes made from dissimilar materials, and due to the fact of experiencing large local deformations ranging from room temperature to above the melting point. Heating is facilitated by resistance heating and is highly influenced by the contact area resulting from the amount of deformation, which is also temperature dependent due to material softening and frictional conditions. Resort to new materials and applications require a new level of understanding of the process by combining finite element modelling and experimentation. This paper draws from the challenge of developing a three-dimensional computer program for electro-thermo-mechanical modeling of resistance welding and presents, as far as the authors are aware, the first ever three-dimensional simulation of the projection welding of square nuts to sheets by means of finite element analysis. Results are compared with experimental observations and measurements produced by the authors with the aim and objective of assessing the accuracy, reliability and validity of the theoretical and numerical developments. Numerical simulations support the evaluation of the experiments by providing detailed information on the process like the initial heating location and the following temperature development, and allowing to analyze the weldability of the square nut to the sheet under different operating conditions. © 2014 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND licens

Multi-objective optimization of die geometry in ingot forging

AbstractThe soundness of an ingot after hot forging with different V-shaped lower dies is evaluated using finite element simulations. Two different modelling approaches that make use of uncoupled ductile damage and coupled ductile damage based on porous plasticity are employed. It is shown that the two approaches provide somewhat different results. A simple quantification scheme is suggested for ranking the overall performance of the different geometries of the V-shaped lower dies. Results show that a lower die angle in the range 90o-120o is capable of ensuring the best results