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Formation mechanism and modeling of surface waviness in incremental sheet forming

《机械工程前沿（英文）》 2022年第17卷第2期 doi: 10.1007/s11465-022-0679-1

摘要： Improving and controlling surface quality has always been a challenge for incremental sheet forming (ISF), whereas the generation mechanism of waviness surface is still unknown, which impedes the widely application of ISF in the industrial field. In this paper, the formation mechanism and the prediction of waviness are both investigated through experiments, numerical simulation, and theoretical analysis. Based on a verified finite element model, the waviness topography is predicted numerically for the first time, and its generation is attributed to the residual bending deformation through deformation history analysis. For more efficient engineering application, a theoretical model for waviness height is proposed based on the generation mechanism, using a modified strain function considering deformation modes. This work is favorable for the perfection of formation mechanism and control of surface quality in ISF.

关键词： surface waviness incremental sheet forming numerical simulation formation mechanism deformation history

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Finite element simulations of sheet metal forming under complex strain paths

CHEN Wei, YANG Jichang, WU Xiaofeng, LU Dun, GUO Weigang

《机械工程前沿（英文）》 2007年第2卷第4期页码 399-403 doi: 10.1007/s11465-007-0069-8

摘要： Fracture is a common defect in sheet metal forming and it is essentially caused by tensile instability. This paper analyzes some experiments and theories for building forming limit diagrams of sheet metal and points out the advantages and disadvantages of current experiments and theories. According to this, a method that integrates the finite element simulation and experiment was used to research the forming limit diagrams of the sheet metal under complex strain paths. Taking the rear hanger that undergoes twice stamping as an example, the strain paths of the dangerous point of the rear hanger is investigated. Finally, the forming method of the rear hanger is confirmed. Results indicate that finite element method (FEM) can achieve the complex strain paths and different strain paths will have great impacts on the result of the sheet metal forming.

关键词： dangerous forming method different hanger forming

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FEM-based strain analysis study for multilayer sheet forming process

Rongjing ZHANG,Lihui LANG,Rizwan ZAFAR

《机械工程前沿（英文）》 2015年第10卷第4期页码 373-379 doi: 10.1007/s11465-015-0371-9

摘要：

Fiber metal laminates have many advantages over traditional laminates (e.g., any type of fiber and resin material can be placed anywhere between the metallic layers without risk of failure of the composite fabric sheets). Furthermore, the process requirements to strictly control the temperature and punch force in fiber metal laminates are also less stringent than those in traditional laminates. To further explore the novel method, this study conducts a finite element method-based (FEM-based) strain analysis on multilayer blanks by using the 3A method. Different forming modes such as wrinkling and fracture are discussed by using experimental and numerical studies. Hydroforming is used for multilayer forming. The Barlat 2000 yield criteria and DYNAFORM/LS-DYNA are used for the simulations. Optimal process parameters are determined on the basis of fixed die-binder gap and variable cavity pressure. The results of this study will enhance the knowledge on the mechanics of multilayer structures formed by using the 3A method and expand its commercial applications.

关键词： finite element method (FEM) strain analysis multilayer sheet forming

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汽车板精益成形技术

林忠钦,李淑慧,王武荣,来新民

《中国工程科学》 2009年第11卷第11期页码 22-29

摘要：

建立了面向零件成形特征的合理选材方法，发明了高效的拉延筋阻力混合优化设计方法，构建了变压边力控制实验平台。从降低成形质量对材料和工艺过程波动敏感性的角度出发，研究面向材料和工艺参数随机波动的成形质量的稳健控制。形成了基于“合理选材、工艺优化、稳健设计”思想的汽车板精益成形技术体系。通过在宝钢股份和多家汽车厂10多年的成功应用，支持宝钢汽车板的市场占有率稳步达到50 %，有效地推动了国产汽车板使用技术的发展。

关键词：汽车板精益成形合理选材工艺优化稳健设计

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西安交通大学先进制造技术研究进展

卢秉恒

《中国工程科学》 2013年第15卷第1期页码 4-8

摘要：

针对中国制造业的第三次浪潮，高端装备的制造技术要求在逐年提高，以飞机为代表的装备制造技术研究是提升我国冷、热加工水平的有效途径。分别从切削加工技术、成形加工技术、增材制造技术阐述了西安交通大学近些年来开展的研究工作，部分研究成果为飞机零部件的加工和制造提供了良好的解决方案，最后回顾了在前沿制造领域如生物制造和微纳制造所开展的研究工作。

关键词：高速切削渐进成形增材制造

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Functional tolerance theory in incremental growth design

YANG Bo, ZE Xiangbo, YANG Tao

《机械工程前沿（英文）》 2007年第2卷第3期页码 336-343 doi: 10.1007/s11465-007-0059-x

摘要： The evolutionary tolerance design strategy and its characteristics are studied on the basis of automation technology in the product structure design. To guarantee a successful transformation from the functional requirement to geometry constraints between parts, and finally to dimension constraints, a functional tolerance design theory in the process of product growth design is put forward. A mathematical model with a correlated sensitivity function between cost and the tolerance is created, in which the design cost, the manufacturing cost, the usage cost, and the depreciation cost of the product are regarded as control constraints of the tolerance allocation. Considering these costs, a multifactor-cost function to express quality loss of the product is applied into the model. In the mathematical model, the minimum cost is used as the objective function; a reasonable process capability index, the assembly function, and assembly quality are taken as the constraints; and depreciation cost in the objective function is expressed as the discount rate terminology in economics. Thus, allocation of the dimension tolerance as the function and cost over the whole lifetime of the product is realized. Finally, a design example is used to demonstrate the successful application of the proposed functional tolerance theory in the incremental growth design of the product.

关键词： successful transformation mathematical automation technology tolerance allocation minimum

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铝合金板材拉伸变形时橘皮成因的研究进展

马鸣图,杨红亚,吴娥梅,金庆生

《中国工程科学》 2014年第16卷第1期页码 4-13

摘要：

本文对铝合金板材拉伸变形时橘皮成因的研究进展进行了评述。首先展示了有无橘皮板材在各种检测仪器下拉伸变形前后的表面形貌、表面滑移带、粗糙度和拉伸断口的形貌，并展示了纳米硬度的测量结果和表征。进一步介绍了最近关于橘皮形成的电子背散射衍射技术（EBSD）的研究成果和X射线对有无橘皮样品的织构测量结果，结合样品的显微组织和力学性能深入分析了橘皮的成因。一系列的结果表明，拉伸变形以后表面橘皮的出现与拉伸变形过程中产生的织构密切相关，而织构的生成又与拉伸过程中晶粒变形的不均匀性有关；晶粒的大小将明显影响变形的不均匀性和织构的生成，粗晶粒比细晶粒更容易产生不均匀变形、晶粒转动和织构，从而导致拉伸变形后生成表面橘皮。由此介绍了粗晶粒和细晶粒拉伸变形后表面状态的示意模型，同时建议对橘皮的形成进行进一步的研究和分析，以完善橘皮成因的定量描述。

关键词：橘皮成因力学性能拉伸断口纳米硬度 EBSD X射线

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Combination form analysis and experimental study of mechanical properties on steel sheet glass fiber

《结构与土木工程前沿（英文）》 2021年第15卷第4期页码 834-850 doi: 10.1007/s11709-021-0743-7

摘要： The concept of steel sheet glass fiber reinforced polymer (GFRP) composite bar (SSGCB) was put forward. An optimization plan was proposed in the combined form of SSGCB. The composite principle, material selection, and SSGCB preparation technology have been described in detail. Three-dimensional finite element analysis was adopted to perform the combination form optimization of different steel core structures and different steel core contents based on the mechanical properties. Mechanical tests such as uniaxial tensile, shear, and compressive tests were carried out on SSGCB. Parametric analysis was conducted to investigate the influence of steel content on the mechanical properties of SSGCB. The results revealed that the elastic modulus of SSGCB had improvements and increased with the rise of steel content. Shear strength was also increased with the addition of steel content. Furthermore, the yield state of SSGCB was similar to the steel bar, both of which indicated a multi-stage yield phenomenon. The compressive strength of SSGCB was lower than that of GFRP bars and increased with the increase of the steel core content. Stress-strain curves of SSGCB demonstrated that the nonlinear-stage characteristics of SSGCB-8 were much more obvious than other bars.

关键词： steel sheet GFRP composite bar combination form numerical modeling mechanical properties test strength

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Preparation and characterization of PVDF-PFSA flat sheet ultrafiltration membranes

Jiquan MA, Junhong ZHAO, Zhongbin REN, Lei LI

《化学科学与工程前沿（英文）》 2012年第6卷第3期页码 301-310 doi: 10.1007/s11705-012-1204-6

摘要： High performance polyvinylidene fluoride (PVDF) flat sheet ultrafiltration (UF) membranes have been prepared by an immersion precipitation phase inversion method using perfluorosulfonic acid (PFSA) as a pore former and as a hydrophilic component of the membranes and polyethylene glycol ( = 400) (PEG400) as a pore forming agent. The effects of the presence of PEG and the concentration of the PFSA on the phase separation of the casting solutions and on the morphologies and performance of UF membranes including their porosity, water flux, rejection of bovine serum albumin (BSA) protein, and anti-fouling property were investigated. Phase diagrams, viscosities and the phase separations upon exposure to water vapor showed that both PEG400 and PFSA promoted demixing of the casting solution. Scanning electron microscopy measurements showed that the PVDF-PFSA blend membranes had more macropores and finger-like structures than the native PVDF membranes. The PVDF-PFSA membrane (5 wt-% PEG400+ 5 wt-% PFSA) had a pure water flux of 141.7 L/m ·h, a BSA rejection of 90.1% and a relative pure water flux reduction (RFR) of 15.28%. These properties were greatly superior to those of the native PVDF membrane (pure water flux of 5.6 L/m ·h, BSA rejection of 96.3% and RFR of 42.86%).

关键词： polyvinylidene fluoride perfluorosulfonic acid polyethylene glycol flat sheet membrane ultrafiltration

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Digital high-efficiency print forming method and device for multi-material casting molds

Zhongde SHAN, Zhi GUO, Dong DU, Feng LIU, Wenjiang LI

《机械工程前沿（英文）》 2020年第15卷第2期页码 328-337 doi: 10.1007/s11465-019-0574-6

摘要： Sand mold 3D printing technology based on the principle of droplet ejection has undergone rapid development in recent years and has elicited increasing attention from engineers and technicians. However, current sand mold 3D printing technology exhibits several problems, such as single-material printing molds, low manufacturing efficiency, and necessary post-process drying and heating for the manufacture of sand molds. This study proposes a novel high-efficiency print forming method and device for multi-material casting molds. The proposed method is specifically related to the integrated forming of two-way coating and printing and the short-flow manufacture of roller compaction and layered heating. These processes can realize the high-efficiency print forming of high-performance sand molds. Experimental results demonstrate that the efficiency of sand mold fabrication can be increased by 200% using the proposed two-way coating and printing method. The integrated forming method for layered heating and roller compaction presented in this study effectively shortens the manufacturing process for 3D-printed sand molds, increases sand mold strength by 63.8%, and reduces resin usage by approximately 30%. The manufacture of multi-material casting molds is demonstrated on typical wheeled cast-iron parts. This research provides theoretical guidance for the engineering application of sand mold 3D printing.

关键词： multi-material casting mold 3D printing efficient print forming method

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radiation and heat source/sink on unsteady MHD boundary layer flow and heat transfer over a shrinking sheet

Krishnendu Bhattacharyya

《化学科学与工程前沿（英文）》 2011年第5卷第3期页码 376-384 doi: 10.1007/s11705-011-1121-0

摘要： In this paper, an investigation is made to study the effects of radiation and heat source/sink on the unsteady boundary layer flow and heat transfer past a shrinking sheet with suction/injection. The flow is permeated by an externally applied magnetic field normal to the plane of flow. The self-similar equations corresponding to the velocity and temperature fields are obtained, and then solved numerically by finite difference method using quasilinearization technique. The study reveals that the momentum boundary layer thickness increases with increasing unsteadiness and decreases with magnetic field. The thermal boundary layer thickness decreases with Prandtl number, radiation parameter and heat sink parameter, but it increases with heat source parameter. Moreover, increasing unsteadiness, magnetic field strength, radiation and heat sink strength boost the heat transfer.

关键词： MHD boundary layer unsteady flow heat transfer thermal radiation heat source/sink shrinking sheet suction/injection

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A hierarchical system to predict behavior of soil and cantilever sheet wall by data-driven models

Nang Duc BUI; Hieu Chi PHAN; Tiep Duc PHAM; Ashutosh Sutra DHAR

《结构与土木工程前沿（英文）》 2022年第16卷第6期页码 667-684 doi: 10.1007/s11709-022-0822-4

摘要： The study proposes a framework combining machine learning (ML) models into a logical hierarchical system which evaluates the stability of the sheet wall before other predictions. The study uses the hardening soil (HS) model to develop a 200-sample finite element analysis (FEA) database, to develop the ML models. Consequently, a system containing three trained ML models is proposed to first predict the stability status (random forest classification, RFC) followed by 1) the cantilever top horizontal displacement of sheet wall (artificial neural network regression models, RANN1) and 2) vertical settlement of soil (RANN2). The uncertainty of this data-driven system is partially investigated by developing 1000 RFC models, based on the application of random sampling technique in the data splitting process. Investigation on the distribution of the evaluation metrics reveals negative skewed data toward the 1.0000 value. This implies a high performance of RFC on the database with medians of accuracy, precision, and recall, on test set are 1.0000, 1.0000, and 0.92857, respectively. The regression ANN models have coefficient of determinations on test set, as high as 0.9521 for RANN1, and 0.9988 for RANN2, respectively. The parametric study for these regressions is also provided to evaluate the relative insight influence of inputs to output.

关键词： finite element analysis cantilever sheet wall machine learning artificial neural network random forest

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Hybrid forming mechanism of patternless casting and laser cladding

Zhongde SHAN, Fuzhen SUN, Yang LIU

《机械工程前沿（英文）》 2019年第14卷第4期页码 393-401 doi: 10.1007/s11465-019-0550-1

摘要： In accordance with the requirement of manufacturing dies quickly and economically, a hybrid forming method of stamping dies for automobile panels is proposed. The method combines digital patternless casting and high-power laser cladding. An experimental study is conducted on the hybrid forming process and its trial production and application in the manufacturing of stamping dies for typical panels. Results prove that the laser cladding layer exceeds HRC60 (Rockwell hardness) and thus meets the production efficiency requirement of automobile dies. The rate of defects is well controlled. Compared with traditional technology, this technology has remarkable advantages and advancement.

关键词： patternless casting laser cladding hybrid forming rapid tooling

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Highlight yield forming and innovative technologies in tropical crops

Wenquan WANG

《农业科学与工程前沿（英文）》 2016年第3卷第4期页码 283-284 doi: 10.15302/J-FASE-2016128

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Properties and effect of forming sewage sludge into lightweight ceramics

Min YUE, Qinyan YUE, Yuanfeng QI, Baoyu GAO, Hui YU

《环境科学与工程前沿（英文）》 2012年第6卷第1期页码 117-124 doi: 10.1007/s11783-010-0220-3

摘要： In this work we investigated the chemical, thermal and toxic properties of dried sewage sludge (DSS), the preparation and properties of lightweight sludge ceramic (LSC) and the mechanisms of action of the organic and inorganic foaming agents (OFAs and IFAs). The chemical components and thermal properties of the raw materials were studied by Energy Dispersive X-ray Detection (EDX) and Thermogravimetric Analysis and Differential Scanning Calorimetry (DSC/TGA). The mineral phases of the raw materials and the formed ceramics were determined by X-ray Diffraction (XRD). The leaching characteristics of heavy metals were investigated with Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES). Different ratios of DSS and clay were mixed and pressed into raw pellets. After drying and preheating treatment, the raw pellets were sintered at 1150°C for 10 min. The physical properties of LSC (50 wt% DSS added) were tested. The results showed that when the addition of DSS was above 50 wt%, LSC began to shrink, and a maximum density occurred. The environmental safety of LSC was satisfactory. XRD showed that some new mineral phases formed in the LSC. Observation of the microstructure by Scanning Electron Microscope (SEM) indicated that the body of LSC was porous.

关键词： sludge foaming agents ceramics preheating process