Dimpling process in cold roll metal forming by finite element modelling and experimental validation

The dimpling process is a novel cold-roll forming process that involves dimpling of a rolled flat strip prior to the roll forming operation. This is a process undertaken to enhance the material properties and subsequent products’ structural performance while maintaining a minimum strip thickness. In order to understand the complex and interrelated nonlinear changes in contact, geometry and material properties that occur in the process, it is necessary to accurately simulate the process and validate through physical tests. In this paper, 3D non-linear finite element analysis was employed to simulate the dimpling process and mechanical testing of the subsequent dimpled sheets, in which the dimple geometry and material properties data were directly transferred from the dimpling process. Physical measurements, tensile and bending tests on dimpled sheet steel were conducted to evaluate the simulation results. Simulation of the dimpling process identified the amount of non-uniform plastic strain introduced and the manner in which this was distributed through the sheet. The plastic strain resulted in strain hardening which could correlate to the increase in the strength of the dimpled steel when compared to plain steel originating from the same coil material. A parametric study revealed that the amount of plastic strain depends upon on the process parameters such as friction and overlapping gap between the two forming rolls. The results derived from simulations of the tensile and bending tests were in good agreement with the experimental ones. The validation indicates that the finite element analysis was able to successfully simulate the dimpling process and mechanical properties of the subsequent dimpled steel products.     

板材数字化成形加工路径规划研究

在板材数字化成形过程中零件的直壁部分常因为金属变形量过大而极易发生破裂 ,故在加工前需要进行适当的路径规划以控制成形中直壁部分金属过度变形 ,使板材整体壁厚变化缓慢而均匀 ,优化其成形过程 ,最终完成薄板材的直壁部分成形。研究了具体的路径规划方法及其加工轨迹自动生成 ,主要从工艺角度对直壁部分成形作了有益的探索     

Analytical prediction of stepped feature generation in multi-pass single point incremental forming

Single point incremental forming (SPIF) is a new sheet metal forming process characterized by higher formability, product independent tooling and greater process flexibility. The inability of conventional single pass SPIF to form vertical walls without failure is overcome by forming multiple intermediate shapes before forming the final component, i.e., multi-pass single point incremental forming (MSPIF). A major issue with MSPIF is significant geometric inaccuracy of the formed component, due to the generation of stepped features on the base. This work proposes analytical formulations that are shown to accurately and quantitatively predict the stepped feature formation in MSPIF. Additionally, a relationship is derived among the material constants used in these analytical equations, the yield stress and thickness of the blank material, such that the computational effort required for the calibration of these constants can be minimized. Finally, the physical effects of yield stress and sheet thickness on the rigid body translation are further discussed.     

External force-assisted laser forming process for gaining high bending angles

Laser forming process is used in forming and bending of metallic and non-metallic sheets. Laser beam irradiation causes a localized temperature increase and a localized mechanical strength decrease. In this article, an external mechanical force is added to a laser beam irradiation, which is called external force-assisted laser forming process, to gain a 90-degree bending angle. Furthermore, Numerical simulation of the process is performed to achieve a good understanding of the process. Simulation results show that more than two-third of the final forming is due to the laser beam irradiation. Equivalent plastic strain values during laser forming and external force-assisted laser forming processes are compared. Results show that equivalent plastic strain in laser forming process increases in a step pattern, with increasing in scan pass numbers. This occurs because when the laser beam irradiates on the sheet surface, it reduces the yield strength of the sheet. Equivalent plastic strain in external force-assisted laser forming process has an oscillatory step nature. This attributes to simultaneous effects of strain hardening and thermal induced reduction of yield strength of the sheet. Simulations were in good accordance with experiments.     

Springback control of sheet metal air bending process

Press brake bending is a commonly used process for sheet metal part fabrication. It has been observed that the final bend angle, which is the angle achieved upon removal of the punch, is smaller than the initial bend angle. This springback is due to the elastic recovery of the sheet metal. Various theoretical models have been proposed to predict the springback using the tooling geometry and the known properties of the sheet metal. However, in a production environment, the actual properties of any given workpiece may vary from the nominal properties of the lot. This variation causes the actual springback to deviate from the theoretical predictions. This paper presents a practical incremental bending methodology to control punch displacement to achieve more accurate final bend angles. In the proposed approach, workpiece properties are estimated from measured loaded and unloaded bend angles. The estimated properties are used to determine the final punch position required to obtain the desired bend angle after springback. A series of bending experiments was performed. It was found that the proposed method can better predict springback and effectively control the bend angle variation in a production environment.     

2618铝合金后摇臂等温体积成形工艺的研究

根据后摇臂技术条件要求，确定了等温成形工艺为最佳成形工艺方案。文中简要介绍了5×l0     

Modeling and simulation of arc: Laser and hybrid welding process

Welding is a fabrication process to join two different materials. Among the many welding processes, the arc and laser welding processes are the most widely used. Great effort is required to understand the physical phenomena of arc and laser welding due to the complex behaviors which include liquid phase, solid phase and, gas phase. So it is necessary to conduct numerical simulation to understand the detailed procedures of welding. This paper will present the various numerical simulation methods of the arc welding processes such as arc plasma, gas tungsten arc welding, gas metal arc welding, laser welding, and laser–arc hybrid welding. These simulations are conducted by the finite element method, finite differential method and volume of fluid method to describe and analyze the various welding processes.     

Modelling of the Lenzing SO2 recovery process and validation with plant data

Mass balances were performed for the recovery absorption stages of a magnesium bisulphite pulping process in order to obtain accurate basic data for further process simulation.Data for the main components (liquid flows, sulphur and magnesium oxide) were obtained at three different power levels of the downstream recovery boiler.Based on these results, single absorption stages were simulated with a commercial modelling package. The results of the mass balance and the results of the simulation of single absorption stages are compared. Furthermore, results simulated with the new model of the whole absorption recovery system are shown and problems, which appeared during the calculation runs, are described.     

Warm forming die design,part I: Experimental validation of a novel thermal finite element modeling code

Finite element analysis (FEA) has become an invaluable tool in the design of sheet metal stamping dies and processes. FEA has gained widespread acceptance as the best method of optimizing dies for conventional stamping processes. More recently, FEA has been shown to be an effective method of designing tooling for sheet forming processes. In this work, an FEA based approach is applied to the warm stamping (warm forming) process. This work introduces a new thermal finite element analysis software called PASSAGE®/Forming (PASSAGE) that enables the up-front design of the thermal management of warm forming dies. This thermal finite element analysis software is designed to specifically handle the forming and optimization scenarios related to the heating of a stamping die while minimizing user interface time. In this work, PASSAGE has been applied to a simple block of steel embedded with cartridge heaters to validate the prediction capability of this software under two different heating conditions. The results show that PASSAGE is capable of predicting the actual steady-state temperature distribution within the block with an acceptable level of accuracy while yielding notable information to the user with respect to specifying power requirements. A finite element software package like PASSAGE is a valuable tool that will aid greatly in the implementation of warm forming as a manufacturing process beyond the scope of the laboratory and into production.     

传统活性污泥法COD去除及脱氮改造的模拟

活性污泥模型方法正逐渐成为废水处理工程领域科学研究、工艺设计和过程控制的一种重要手段。以国际水质协会的活性污泥1号模型（ASM1为基础，以MATLAB为工具开发模拟软件，对模型进行了校核与验证。模拟了重庆市唐家桥污水处理厂COD和含N组分的降解过程，研究了有机物负荷、流量、温度和溶解氧浓度变化对出水COD、氨氮、硝态氮和总氮的影响。利用所开发的模拟程序对唐家桥污水处理厂的脱氮改造方案进行了优化，并预测了改造后的处理效果。     

基于PHREEQC程序的磷酸铵镁结晶法污水处理工艺模型化研究

为揭示溶液物化参数对磷酸铵镁结晶工艺回收氮、磷的影响,利用地球化学水质模型程序PHREEQC 2.11计算了涵盖实际工况条件下可能存在的溶液体系的磷酸铵镁饱和度指数,对溶液组分的浓度效应进行了模型化热力学评估.模拟溶液体系含磷10～600 mg·L-1、镁24～720 mg·L-1,其氨氮与磷的摩尔比为1～40,温度为25℃,pH值为6.0～12 0.计算结果表明,磷酸铵镁的饱和度指数与氮、磷、镁的质量浓度分别呈对数函数关系,并随任何一个因子的增大而增大;与溶液pH值呈多项式函数关系,结晶反应的最佳pH值为9.0,并随溶液中氨氮与磷摩尔比的增大而略升;此外,磷酸铵镁的饱和度指数与溶液离子强度呈幂函数关系,随离子强度的增大而减小.适当调节溶液的镁盐浓度和控制溶液pH值,是调控磷酸铵镁结晶反应,实现氮、磷回收的2种主要手段.     

Development of a biaxial loading frame for sheet metal

Characterization of the evolving yield loci and forming limit diagrams for sheet materials under biaxial loading is necessary for the development of accurate sheet metal forming process simulations. Biaxial tension testing has been shown to have significant advantages over the current computational and experimental methods for such material characterization; however, the few commercially available loading frames are far too large and expensive to be practical for most metal forming research laboratories. In this paper, the design of a practical servohydraulic biaxial loading frame is presented. The design, control, and operation of the loading frame are discussed in detail, and experimental data is provided to validate the effectiveness of the control system with respect to specimen center shifting.     

LDR and hydroforming limit for deep drawing of AA5754 aluminum sheet

The goal of the research was to determine the limits and conditions in which the sheet hydroforming process provides a significant advantage over stamping in deep drawing of AA5754 aluminum sheets. Specifically, the maximum draw depth achievable by stamping, warm stamping (WF), sheet hydroforming (SHF), and sheet thermo-hydroforming (THF) of AA5754 aluminum alloy were quantified through experimental and computational modeling. A limited number of forming experiments were conducted with AA5754 aluminum sheets using a cylindrical punch and counteracting fluid at different temperatures and pressures. Several parameters, such as force–displacement, hydroforming pressure and temperature, and the maximum draw depth prior to wrinkling or tearing were measured during the forming process to make comparisons with simulations. The computational study included the simulation of stamping, WF, SHF and THF of AA5754 aluminum sheet with the LS-Dyna code, and the Barlat 2000-2d yield function with temperature-dependent coefficients. To predict the onset of wrinkling and tearing, the numerically generated, temperature-dependent forming limit diagrams (FLDs) based on the Barlat 2000-2d yield function were used. It was found that compared with stamping, SHF and THF can achieve more than 100% deeper draw depths with AA5754 aluminum sheet. The stamping simulations were used also to calculate the optimum blank size and die corner radii for the limiting draw ratio (LDR). The LDR was found to be very sensitive to the punch and die corner radii used in the experiments, which represent the curvature of character lines in an actual part. The LDR for AA5754 aluminum sheet was found to be 1.33 and 2.21 for sharp and round die corner radii, respectively. Overall, it was concluded that SHF is most ideal for deep drawing of aluminum sheets with sharp radii features. With the additional drawability provided by SHF, the automotive industry would be able to make difficult-to-form aluminum parts that cannot be stamped without product concessions such as increasing the die radii.     

护板双向对称成形模设计

通过汽车制动阀安装板的护板成形模设计，说明了受力不均匀，有方向相反、弯曲高度、宽度尺寸不等的成形件，可采用对称的方法一次成形，对同类零件的模具设计有一定的参考价值。     

Production and characterization of bioaerosols for model validation in spacecraft environment

This study aimed to evaluate the suitability of two bioaerosol generation systems(dry and wet generation) for the aerosolization of microorganisms isolated from the International Space Station, and to calibrate the produced bioaerosols to fulfill the requirements of computational fluid dynamics model(CFD) validation. Concentration, stability, size distribution, agglomeration of generated bioaerosol and deposition of bioaerosols were analyzed. In addition, the dispersion of non-viable particles in the air was studied.Experiments proved that wet generation from microbial suspensions could be used for the production of well-calibrated and stabile bioaerosols for model validation. For the simulation of the natural release of fungal spores, a dry generation method should be used. This study showed that the used CFD model simulated the spread of non-viable particles fairly well. The mathematical deposition model by Lai and Nazaroff could be used to estimate the deposition velocities of bioaerosols on surfaces, although it somewhat underestimated the measured deposition velocities.     

Experimental analysis of friction stir forming for dissimilar material joining application

Mass reduction of automotive body structures is a critical part of achieving reduced CO₂ emissions in the automotive industry. There has been significant work on the application of ultra high strength steels and aluminum alloys. However, the next paradigm is the integrated use of both materials, which poses a challenge of how to join the dissimilar materials. Friction stir forming is a new manufacturing process for joining dissimilar materials. The concept of this process is stir heating one material and forming it into a mechanical interlocking joint with the second material. In this research the process was experimentally analyzed in a position controlled robotic friction stir welding machine between aluminum and steel workpieces. New tool geometries were evaluated toward the goal of optimizing joint strength. The significant process parameters were identified and their optimized settings for the current experimental conditions defined using a design of experiments methodology. A scanning electron microscope was used to characterize the bonding and joint structure for single and multi-pin configurations. Two failure modes, aluminum sheet peeling and bonding delamination, i.e. braze fracture, were identified. It was found that the presence of zinc coating on the steel and overall joint geometry greatly affected the joint strength. The aluminum–zinc braze joint appears to be the largest contributor to joint strength for the single-pin joint configuration. The multi-pin geometry enabled a distribution of load to the four pins following fracture of the braze for increased joint toughness and ductility. Thus, the FSF method has been shown to exhibit potential for joining of aluminum to steel.     

全民所有自然资源资产负债表编制的思路框架

编制全民所有自然资源资产负债表是对我国自然资源资产负债表编制理论与方法体系的完善,也是新时期促进生态文明建设的重要举措。在理清全民所有自然资源资产负债表与自然资源资产负债表的区别和联系基础上,提出了符合用途管制和产权设置要求的自然资源资产确认方法以及自然资源保护和利用负债确认方法,初步构建了"主表+分表+基础表"的报表体系,设计出全民所有自然资源资产负债总体情况表、当期实际供应表和当期实际供应流向表三张主表。通过报表编制,反映全民所有自然资源资产家底以及占有、使用、收益、处分等各项所有权权利实现情况,以期为维护国家所有者权益、促进自然资源保护和合理利用、支撑国民经济发展提供基础信息支撑。     

表面形貌和润滑条件对轿车用国产冷轧薄板的成形性影响

在大量实验的基础上就轿车用国产冷轧薄板的表面粗糙度、表面微观形貌及表面润滑条件等因素对钢板成形性的影响作了详细的探讨，并认为润滑有利于金属薄板在冲压成形过程中的流动，可使整个零件的应变分布趋于均匀，从而提高零件的冲压成形能力，降低冲压件的废品率。     

土壤污染调查加密布点优化方法构建及验证

鉴于传统调查布点方法对土壤污染物平均含量的估计精度较高,但对污染区范围的估计精度不能满足修复治理需求的问题,同时,为了准确估计土壤污染区面积及其空间位置,提出了土壤污染详查样点优化方法.在初步调查的基础上,首先利用地统计条件模拟方法预测土壤污染概率,基于污染概率和土壤污染物含量局部空间变异确定加密布点的优先区域,并根据污染物含量的空间变化趋势布设样点,然后根据优化后的土壤污染调查布点方案估计污染区面积和空间位置.最后,以某Cd污染场地为例,验证了布点优化方法的效果.结果表明,土壤污染调查加密布点方法显著提高了污染区面积及其空间位置的估计精度.案例场地土壤Cd污染区面积的预测误差为4.10%,污染区空间位置的精度为86.10%.土壤污染调查布点优化方法在保证土壤污染调查精度的同时,相比于传统调查方法可显著降低土壤污染调查的样本量.     

Properties and effect of forming sewage sludge into lightweight ceramics

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.