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The paper deals with simulation of ejection of thermoplastic moldings from an injection mold using a consecutive combination of finite element mold filling and mechanical analyses. A new software system was developed able to predict the ejection forces, deformed shape, stresses and strains during the ejection phase of the injection molding process. A simple case study demonstrates that ejection parameters and even feasibility of the ejection itself are strongly dependent upon geometrical parameters of the moldings and design of the mold and that simple formulas are not adequate for ejection analysis. [ABSTRACT FROM AUTHOR]

The current paper intends to realise a fast method for determining the material characteristics in the case of composite materials used in the airbags manufacturing. For determining the material data needed for other complex numerical simulations at macroscopic level there was used the inverse analysis method. In fact, there were carried out tensile tests for the composite material extracted along two directions - the direction of the weft and the direction of the warp and afterwards there were realised numerical simulations (using the Ls-Dyna software). A second stage consisted in the numerical simulation through the finite element method and the experimental testing for the Bias test. The material characteristics of the composite fabric material were then obtained by applying a multicriterial analysis using the Ls-Opt software, for which there was imposed a decrease of the mismatch between the force-displacement curves obtained numerically and experimentally, respectively, for both directions (weft and warp) as well as the decrease of the mismatch between the strain - extension curves for two points at the Bias test. [ABSTRACT FROM AUTHOR]

The paper presents a comparison study based on the numerical simulation with the finite element method (using the Ls-Dyna software) of incremental sheet metal forming and experimental researches regarding the same process. For this comparison study we selected four different shell formulations: Belytschko-Tsay (shell formulation number 2), fully-integrated shell formulation (shell formulation number 16) and two relatively new shell formulations Belytschko-Tsay with thickness-stretch (shell formulation number 25) and fully integrated with thickness-stretch (shell formulation number 26). In order to compare the results of the numerical simulations with the results of the experimental researches we focused on the maximum values of the main's strains, the thickness reduction and the forces on two directions. [ABSTRACT FROM AUTHOR]

A novel flexible roll forming method is proposed for manufacturing of large curved metal plates. By adjusting the position of three rows of staggered arranged rollers, a large curved metal plate is formed in an incremental way. In this paper, FE (finite element) model is established to analyze the stress-strain distribution of the deformed plates in the forming process. Based on the numerical simulation, the influence of the relative position between upper rollers and lower rollers on the dimensional accuracy of the large curved metal plate is studied. Comparison results show that roller arrangement has great influence on the dimensional accuracy of deformed plates, and process with staggered arranged rollers has the best dimensional accuracy. [ABSTRACT FROM AUTHOR]

This paper presents a finite element (FE) methodology for predicting the distribution of vapor pressure in a simple FR4-copper composite material when it is heated up to 215°C. A general purpose finite element software was used to develop a two-dimensional plane strain model of the composite material. FE simulation of transient moisture absorption was performed to predict the distribution of wetness fraction in the material after pre-conditioning at an 85°C/85%RH environment for 15 days. FE simulation of transient moisture desorption was carried out at the peak solder reflow temperature of 215°C to predict new distribution of wetness fraction in the material. The results of the moisture desorption analysis were used to compute the magnitude of vapor pressure in the material and its distribution at 215°C. It was found that the moisture in the material redistributes itself during solder reflow. The moisture concentration in the area close to the FR4-copper interface below the longer copper trace increases during the solder reflow. The magnitude of the vapor pressure in 70% of the FR4 and near the FR4-copper interface below the lower copper trace is closed to the saturation pressure of water vapor at 215°C. The distribution of the vapor pressure in the material is in similar fashion as the new distribution of wetness fraction after the moisture desorption analysis. [ABSTRACT FROM AUTHOR]

The paper is focused on application of multi-scale 2D method. Model approach consists of Cellular Automata (CA) model of microstructure development and the finite element code to solve thermo-mechanical problem. Dynamic recrystallization phenomenon is taken into account in 2D CA model which takes advantage of explicit representation of microstructure, including individual grains and grain boundaries. Flow stress is the main material parameter in mechanical part of FE and is calculated on the basis of average dislocation density obtained from CA model. The results attained from the model were validated with the experimental data. In the present study, austenitic steel X3CrNi18-10 was investigated. The examination of microstructure for the initial and final microstructures was carried out, using light microscopy and transmission electron microscopy. [ABSTRACT FROM AUTHOR]

In this paper, an analytical solution of micro-scale milling process is presented in order to suggest available machining conditions. The size effect should be considered to determine cutting characteristics in micro-scale cutting. The feed per tooth is the most dominant cutting parameter related to the size effect in micro-scale milling process. In order to determine the feed per tooth at which chips can be formed, the finite element method is used. The finite element method is employed by utilizing the Johnson-Cook (JC) model as a constitutive model of work material flow stress. Machining experiments are performed to validate the simulation results by using a micro-machining stage. The validation is conducted by observing cutting force signals from a cutting tool and the conditions of the machined surface of the workpiece. [ABSTRACT FROM AUTHOR]

In this paper, we focus on the simulation of linear elastic behaviour of plates using a 3D approach which numerical cost only scales like a 2D one. In the case of plates, the kinematic hypothesis introduced in plate theories to go from 3D to 2D is usually unsatisfactory where one cannot rely on St Venant's principle (usually close to the plate edges). We propose to apply the PGD (Proper Generalized Decomposition) method [1] to the simulation of the linear elastic behavior of plates. This method allows us to separately search for the in-plane and the out-of plane contributions to the 3D solution, yielding significant savings in computational cost. The method is validated on a simple case and its full potential is then presented for the simulation of the behavior of laminated composite plates. [ABSTRACT FROM AUTHOR]

This paper presents the formulation of an axi-symmetric element based on an efficient method called 'Inverse Approach' (I.A.) for the numerical modeling of cold forging process. In contrast to the classical incremental methods, the Inverse Approach exploits the known shape of the final part and executes the calculation from the final part to the initial billet. The assumptions of the proportional loading and the simplified tool actions make the I.A. calculation very fast. The metal's incompressibility is ensured by the penalty method. The comparison with ABAQUS® and FORGE® shows the efficiency and limitations of the I.A. This simplified method will be a good tool for the preliminary preform design. [ABSTRACT FROM AUTHOR]

In cold extrusion of steel tools make direct contact with the metal to be extruded. Those tools are exposed to high contact stresses which, in certain cases, may be limiting factors in applying this technology. The present paper was bound to the influence of punch head design on radial stress at the container wall in the process of cold backward extrusion. Five different punch head geometries were investigated. Radial stress on the container wall was measured by pin load cell technique. Special tooling for the experimental investigation was designed and made. Process has been analyzed also by FE method. 2D models of tools were obtained by UGS NX and for FE analysis Simufact Forming GP software was used. Obtained results (experimental and obtained by FE) were compared and analyzed. Optimal punch head geometry has been suggested. [ABSTRACT FROM AUTHOR]

Cage roll forming is one of the advanced methods of cold roll forming process which is used widely for producing ERW pipes. In addition to decreasing the production cost and time, using cage roll forming provides smooth deformation on the strip. Few studies can be found about cage roll forming because of its complexity, and the available knowledge is experience-based more than science-based. In this paper, deformation of pipes with low ratio of thickness/diameter is investigated by 3D finite element simulation in Marc-Mentat software. Edge buckling defect in cage roll forming of low ratio of thickness/diameter pipes is very important. Due to direct influence of longitudinal strain on the edge buckling phenomenon, longitudinal strains at the edge and center line of the strip are investigated and high risk stands are introduced. The deformed strip is predicted using the simulation results and effects of each cage forming stage on the deformed strip profile are specified. In order to verify the simulation results, strip width and opening distance of the two edges in different forming stages are obtained from the simulations and compared with the experimental data which were measured from the production line. A good agreement between the experimental and simulated results is observed. [ABSTRACT FROM AUTHOR]