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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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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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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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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

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Transient performance comparison of grid-forming converters with different FRT control strategies

《能源前沿（英文）》 2023年第17卷第2期页码 239-250 doi: 10.1007/s11708-022-0856-2

摘要： Grid-forming converters (GFMs) are faced with the threat of transient inrush current and synchronization instability issues when subjected to grid faults. Instead of disconnecting from the grid unintentionally, GFMs are required to have fault ride through (FRT) capability to maintain safe and stable operation in grid-connected mode during grid fault periods. In recent studies, different FRT control strategies with distinguishing features and that are feasible for different operation conditions have been proposed for GFMs. To determine their application scope, an intuitive comparison of the transient performance of different FRT control strategies is presented in this paper. First, three typical FRT control strategies (virtual impedance, current limiters, and mode-switching control) are introduced and transient mathematical models are established. A detailed comparison analysis on transient inrush current and transient synchronization stability is then presented. The results will be useful for guiding the selection and design of FRT control strategies. Finally, simulation results based on PSCAD/EMTDC are considered to verify the correctness of the theoretical analysis.

关键词： grid-forming converters (GFMs) fault ride through (FRT) transient stability transient inrush current transient modeling

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复杂曲面薄壁构件流体压力成形理论与技术研究进展 Review

苑世剑

《工程（英文）》 2021年第7卷第3期页码 358-366 doi: 10.1016/j.eng.2020.08.014

摘要：

面向航空航天、汽车和高速列车等工业领域迫切需求的管、板和壳三类典型结构以及难变形材料构件，新一代流体压力成形技术得到迅速发展。本文系统介绍了管类构件低载荷液压成形、板类构件双向加压成形、椭球壳体无模液压成形和难变形材料双调热介质成形理论与工艺的最新研究进展，重点阐述了变形行为、应力调控、缺陷控制和典型应用。此外，本文还展望了流体压力成形技术的未来发展方向，包括超大尺度非均质构件超低载荷成形、金属间化合物和高熵合金构件精密成形、智能化流体压力成形工艺与装备，以及非均质强各向异性薄壳的精确有限元仿真。

关键词：流体压力成形液压成形热介质压力成形薄壁构件应力状态

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汽车轻量化技术：铝/镁合金及其成型技术发展动态

付彭怀,彭立明,丁文江

《中国工程科学》 2018年第20卷第1期页码 84-90 doi: 10.15302/J-SSCAE-2018.01.012

摘要：

为了推动我国汽车工业轻量化进程，文章从新材料、成型新技术、新应用三个方面对铝合金、镁合金两类轻金属材料的国内外研究动态进行了回顾，分析了两类轻金属材料在汽车工业应用的阻力，提出了我国汽车工业铝/镁合金可能的发展建议。

关键词：汽车轻量化铝合金镁合金成型技术发展动态

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材料塑性成形与热处理一体化工程的理论基础

徐祖耀

《中国工程科学》 2004年第6卷第1期页码 16-21

摘要：

材料塑性成形与热处理一体化工程的理论基础，主要为应力—相变—形变间冶金交互作用和力学交互作用的机制、建模以及组织与性能变化的模拟。以钢为例，介绍了应力下铁素体、珠光体相变的文献工作，并提出0.38C-Cr-Mo钢在应力下铁素体形成和珠光体相变的动力学模型以及组织变化的计算机模拟；讨论了Scheil相加性原则的不足及其修正途径；略述应力对钢中贝氏体相变及马氏体相变的影响；简介相场理论及其应用。对材料在应力下相变理论、建模与组织模拟的后续研究工作提出了展望。

关键词：塑性成形—热处理应力下相变相变建模组织模拟 Scheil原则相场理论

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金属板料激光喷丸成形新技术

周建忠,张兴权,王广龙,杨超君,张永康

《中国工程科学》 2005年第7卷第11期页码 94-97

摘要：

激光喷丸塑性成形金属板料是从激光强化发展起来的新技术。当激光诱导冲击波的峰值超过材料的动态屈服极限时，板料冲击区的表层发生微观塑性变形，导致了板料厚度方向上不均勻应力分布，使板料发生宏观变形。不同的激光脉冲参数在板料内部产生不同的残余应力，不同的残余应力使板料发生不同的变形，通过控制喷丸的工艺参数来控制板料内部应力场的精确分布，就可实现板料的精确变形。其显著特点是成形精确，且表层留有有益的残余压应力。

关键词：激光喷丸成形金属板料残余应力

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Experimental research on ductile fracture criterion in metal forming

Song YU, Weiming FENG

《机械工程前沿（英文）》 2011年第6卷第3期页码 308-311 doi: 10.1007/s11465-011-0233-z

摘要：

Ductile fracture criterion is key limitation parameter in material forming. Accuracy predicting surface and internal failure in plastic deformation process affects on the technology design of workpiece and die greatly. Tension, compression, torsion and shearing test on 45# steel are utilized for providing the experimental values of the critical values at fracture, and 11 widely used ductile fracture criterion are selected to simulate the physical experiments and their relative accuracy for predicting and quantifying fracture initiation sites are investigated. The comparing results show that metal forming process under high triaxiality can be estimated successively using both Normalized Cockcroft-latham and the Brozzo ductile fracture criteria, but the Ayada and general Rice-Tracey model work very well for the low triaxiality cases.

关键词： ductile fracture criteria metal forming process material experiment stress triaxiality

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isothermal local loading transitional region of a Ti-alloy rib-web component based on dual-response surface method

Ke WEI, Xiaoguang FAN, Mei ZHAN, Miao MENG

《机械工程前沿（英文）》 2018年第13卷第3期页码 376-384 doi: 10.1007/s11465-018-0500-3

摘要：

Billet optimization can greatly improve the forming quality of the transitional region in the isothermal local loading forming (ILLF) of large-scale Ti-alloy rib-web components. However, the final quality of the transitional region may be deteriorated by uncontrollable factors, such as the manufacturing tolerance of the preforming billet, fluctuation of the stroke length, and friction factor. Thus, a dual-response surface method (RSM)-based robust optimization of the billet was proposed to address the uncontrollable factors in transitional region of the ILLF. Given that the die underfilling and folding defect are two key factors that influence the forming quality of the transitional region, minimizing the mean and standard deviation of the die underfilling rate and avoiding folding defect were defined as the objective function and constraint condition in robust optimization. Then, the cross array design was constructed, a dual-RSM model was established for the mean and standard deviation of the die underfilling rate by considering the size parameters of the billet and uncontrollable factors. Subsequently, an optimum solution was derived to achieve the robust optimization of the billet. A case study on robust optimization was conducted. Good results were attained for improving the die filling and avoiding folding defect, suggesting that the robust optimization of the billet in the transitional region of the ILLF was efficient and reliable.

关键词： isothermal local loading forming rib-web component transitional region robust optimization dual response surface method

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基于动力学的大块金属玻璃形成能力研究

蔡安辉,潘冶,孙国雄,阮许平

《中国工程科学》 2004年第6卷第1期页码 68-73

摘要：

快速判定大块金属玻璃（BMG）的玻璃形成能力（GFA）是开发新型BMG的关键。基于加和性原则，用动力学理论解释了约化玻璃转变温度T_rg作为合金玻璃形成能力的可行性和局限性，为制备非晶合金提供了理论依据，合金能形成BMG的最低T_rg为0.4066，同时找到了玻璃形成能力最佳的两个理论约化玻璃温度，即 T_rg=1和T_rg=0；提出了判定GFA大小及其稳定性的两个新的参量摩尔熔化热ΔH_mg和稳定性CPS，并用它计算了BMG合金系的GFA大小及其稳定性，BMG的GFA大小顺序与井上明久（Inoue）的排列顺序吻合较好。同时，按照BMG合金Z_max和R_c的平均变化对其进行了检验，两者均吻合很好。ΔH_mg的大小是一种快速评价BMG的GFA能力及其稳定性的好方法。

关键词：动力学大块金属玻璃玻璃形成能力加和原则稳定性