Recent Achievements in Numerical Simulation in Sheet Metal Forming Processes

Purpose of this paper: During the recent 10-15 years, Computer Aided Process Planning and Die Design evolved as one of the most important engineering tools in sheet metal forming, particularly in the automotive industry. This emerging role is strongly emphasized by the rapid development of Finite Element Modelling, as well. The purpose of this paper is to give a general overview about the recent achievements in this very important field of sheet metal forming and to introduce some special results in this development activity. Design/methodology/approach: Concerning the CAE activities in sheet metal forming, there are two main approaches: one of them may be regarded as knowledge based process planning, whilst the other as simulation based process planning. The author attempts to integrate these two separate developments in knowledge and simulation based approach by linking commercial CAD and FEM systems. Findings: Applying the above approach a more powerful and efficient process planning and die design solution can be achieved radically reducing the time and cost of product development cycle and improving product quality. Research limitations: Due to the different modelling approaches in CAD and FEM systems, the biggest challenge is to enhance the robustness of data exchange capabilities between various systems to provide an even more streamlined information flow. Practical implications: The proposed integrated solutions have great practical importance to improve the global competitiveness of sheet metal forming in the very important segment of industry. Originality/value: The concept described in this paper may have specific value both for process planning and die design engineers

Numerical modelling and simulation in sheet metal forming

The application of numerical modelling and simulation in manufacturing technologies is looking back over about a 20–30 years history. In recent years, the role of modelling and simulation in engineering and in manufacturing industry has been continuously increasing. It is well known that during manufacturing processes simultaneous the effect of many different parameters can be observed. This is the reason why in former years, detailed analysis of manufacturing processes could have been done only by time-consuming and expensive trial-and-error methods. Due to the recent developments in the methods of modelling and simulation, as well as in computational facilities, modelling and simulation has become an everyday tool in engineering practice. Besides the aforementioned facts, the emerging role of modelling and simulation can also be explained by the growing globalisation and competition of the world market requiring shorter lead times and more cost effective solutions. In spite the enormous development of hardware and software facilities, the exclusive use of numerical modelling still seems to be very time- and cost consuming, and there is still often a high scepticism about the results among industrialists. Therefore, the purpose of this paper is to overview the present situation of numerical modelling and simulation in sheet metal forming, mainly from the viewpoint of scientific research and industrial applications

Integrated Process Simulation and Die Design in Sheet Metal Forming

During the recent 10-15 years, Computer Aided Process Planning and Die Design evolved as one of the most important engineering tools in sheet metal forming, particularly in the automotive industry. This emerging role is strongly emphasized by the rapid development of Finite Element Modelling, as well. The purpose of this paper is to give a general overview about the recent achievements in this very important field of sheet metal forming and to introduce some special results in this development activity. Therefore, in this paper, an integrated process simulation and die design system developed at the University of Miskolc, Department of Mechanical Engineering will be analysed. The proposed integrated solutions have great practical importance to improve the global competitiveness of sheet metal forming in the very important segment of industry. The concept described in this paper may have specific value both for process planning and die design engineers

Statistical Thermodynamics

Contains a report on a research project.United States Air Force, Office of Scientific Research, Air Research and Development Command (Contract AF49(638)-95

Statistical Thermodynamics

Contains reports on one research project.U.S. Air Force (Office of Scientific Research, Air Research and Development Command) under Contract AF49(638)-9

Development of Lightweight Steels for Automotive Applications

The automotive industry plays a determinant role in the economy of developed countries. Sheet metal forming is one of the most important processes in car manufacturing. Recent trends in car production may be characterized by the application of lightweight principles. Its main priority is to fulfill both the customers’ demands and the increased legal requirements. The application of high strength steels may be regarded as one of the potential possibilities. Applying high strength steels has a positive response for many of the requirements: increasing the strength may lead to the application of thinner sheets resulting in significant mass reduction. Mass reduction is leading to lower consumption with increased environment protection. However, increasing the strength can often lead to the decrease of formability, which is very unfavorable for the forming processes. In this chapter, an overview of recent material developments in the automotive industry concerning the use of new-generation high strength steels will be given. In this paper, the material developments are emphasized from the point of view sheet metal forming; therefore, our focus is on the body-in-white manufacturing in the automotive industry

GIS-BASED SUITABILITY MODELING AND MULTI-CRITERIA DECISION ANALYSIS FOR UTILITY SCALE SOLAR PLANTS IN FOUR STATES IN THE SOUTHEAST US

Photovoltaic (PV) development shows significantly smaller growth in the Southeast U.S., than in the Southwest; which is mainly due to the low cost of fossil-fuel based energy production in the region and the lack of solar incentives. However, the Southeast has appropriate insolation conditions (4.0-6.0 KWh/m2/day) for photovoltaic deployment and in the past decade the region has experienced the highest population growth for the entire country. These factors, combined with new renewable energy portfolio policies, could create an opportunity for PV to provide some of the energy that will be required to sustain this growth. The goal of the study was to investigate the potential for PV generation in the Southeast region by identifying suitable areas for a utility-scale solar power plant deployment. Four states with currently low solar penetration were studied: Georgia, North Carolina, South Carolina and Tennessee. Feasible areas were assessed with Geographic Information Systems (GIS) software using solar, land use and population growth criteria combined with proximity to transmission lines and roads. After the GIS-based assessment of the areas, technological potential was calculated for each state. Multi-decision analysis model (MCDA) was used to simulate the decision making method for a strategic PV installation. The model accounted for all criteria necessary to consider in case of a PV development and also included economic and policy criteria, which is thought to be a strong influence on the PV market. Three different scenarios were established, representing decision makers\u27 theoretical preferences. Map layers created in the first part were used as basis for the MCDA and additional technical, economic and political/market criteria were added. A sensitivity analysis was conducted to test the model\u27s robustness. Finally, weighted criteria were assigned to the GIS map layers, so that the different preference systems could be visualized. As a result, lands suitable for a potential industrial-scale PV deployment were assessed. Moreover, a precise calculation for technical potential was conducted, with a capacity factor determined by the actual insolation of the sum of each specific feasible area. The results of the study showed that, for a utility-scale PV utility deployment, significant amount of feasible areas are available, with good electricity generation potential Moreover, a stable MCDA model was established for supporting strategic decision making in a PV deployment. Also, changes of suitable lands for utility-scale PV installations were visualized in GIS for the state of Tennessee

Plant structural complexity and mechanical defenses mediate predator-prey interactions in an odonate-bird system.

Habitat-forming species provide refuges for a variety of associating species; these refuges may mediate interactions between species differently depending on the functional traits of the habitat-forming species. We investigated refuge provisioning by plants with different functional traits for dragonfly and damselfly (Odonata: Anisoptera and Zygoptera) nymphs emerging from water bodies to molt into their adult stage. During this period, nymphs experience high levels of predation by birds. On the shores of a small pond, plants with mechanical defenses (e.g., thorns and prickles) and high structural complexity had higher abundances of odonate exuviae than nearby plants which lacked mechanical defenses and exhibited low structural complexity. To disentangle the relative effects of these two potentially important functional traits on nymph emergence-site preference and survival, we conducted two fully crossed factorial field experiments using artificial plants. Nymphs showed a strong preference for artificial plants with high structural complexity and to a lesser extent, mechanical defenses. Both functional traits increased nymph survival but through different mechanisms. We suggest that future investigations attempt to experimentally separate the elements contributing to structural complexity to elucidate the mechanistic underpinnings of refuge provisioning