Burst speed prediction and reliability assessment of turbine disks: Experiments and probabilistic aspects

With the promotion of advanced manufacturing concepts such as green, high efficiency and intelligence, the shortboard and development bottleneck of traditional forming technology are increasingly prominent. The traditional forming technology is difficult to meet the actual needs of modern production. Special forming methods have emerged. The piercing process of sheet assisted by magnetic medium is an innovative attempt. However, there are many factors that affect the process, and the multi-field coupling further improves the process complexity, so it is very important to design the experimental scheme scientifically and reasonably. In this paper, through the design of orthogonal experiment, the piercing experiments are carried out under the condition of various process parameters, and then with the help of the grey correlation theory analysis, the relative rollover and the width of the relative bright zone are taken as the evaluation indexes. Through the analysis of range and analysis of variance, to find the key factors affecting the quality of piercing, determine the best combination of process parameters, and verify the accuracy of the results by confirming the test. The results show that: the best process combination scheme is A2B3C2D3. The experiments were carried out according to the recommended optimization scheme, the relative rollover reduced to 1.19%, and the proportion of the width of relative bright area reaches 64.06%. This paper provides scientific guidance for the research and quality improvement of piercing technology assisted by magnetic medium.

Comprehensive evaluation of process parameters optimization for sheet piercing assisted by magnetic medium based on grey relational analysis

In this study, experimental and numerical investigations were carried out to achieve a comprehensive understanding of the impact of surface conditions on self-piercing riveting (SPR) joint quality. Oil lubrication and sandpaper grinding were employed in experimental tests to change surface conditions at rivet/top sheet, top/bottom sheets and bottom sheet/die interfaces. A finite element (FE) model for the SPR process was also adopted to numerically assess the impact of surface conditions. Variations in surface conditions were modelled by changing friction coefficients at contact interfaces. The results revealed that the friction coefficient between the rivet and top sheet (μ1) imposed significant influences on the interlock (I1) by affecting the deformation of the rivet shank and top sheet. The friction coefficient between the rivet and bottom sheet (μ2) showed a lower influence on the joint quality because of a smaller contact area and shorter interaction time. The friction coefficient between the top and bottom sheets (μ3) led to opposite changing trends of remaining bottom sheet thickness at the joint centre (tc) and under the rivet tip (ttip). The friction coefficient between the bottom sheet and die (μ4) demonstrated crucial influences on the remaining bottom sheet at the joint centre. The riveting force was significantly influenced throughout the whole riveting process by the μ1, but only affected at the end of the joining process by the other three friction coefficients.

/pdf/experimental-and-numerical-investigations-on-the-impact-of-3gqxcv3c.pdf

Experimental and Numerical Investigations on the Impact of Surface Conditions on Self-Piercing Riveted Joint Quality

Abstract In this study, the effect of the Lode angle on failure and plasticity is considered, and a new Lode angle function on plasticity is developed. Meanwhile, a new temperature coefficient function is proposed in this model, and the application of the model is extended to the range from room temperature to 650°C. The tensile specimens of different shapes have been designed to calibrate the parameters of the model. The tensile tests are carried out on the in situ micro‐tensile machine. For the notched tensile specimens at room temperature to validate the constitutive model, numerical results are consistent with experimental ones well, with an error of 7%. Then, the calibrated model is applied to FE simulations to numerically study the fracture phenomena observed in the test. The fracture positions and damage initiation positions of the shear specimen and the notched tensile specimen can be predicted by FE simulations well, while the smooth tensile specimen cannot be predicted well due to real specimens' imperfections. 

Experimental and numerical investigation of ductile fracture of K418 on in‐situ tensile tests

According to the structural characteristics and technical requirements of cold- forming profiles,the reasonable pressing technology scheme was worked out. The effect of different pressing technology on sheet- flow behavior was analyzed. The structure,work process and design of push and extrusion compound stamping die were introduced. Its compact structure,high efficiency and safe operation enable cold-forming profiles to locate accurately,form quickly and calibrate precisely.

The pressing technology and die design of cold-forming profile

Experimental and numerical study based on ductile failure for the tri-hub burst of turbocharger turbine

The self-piercing riveting process of 6016 aluminum alloy with 1 mm thickness and DC03 structural steel with 15 mm thickness was studied, the process of self-piercing riveting of dissimilar materials between 6016 aluminum alloy and DC03 steel plate is simulated based on DEFORM-2D, and the riveting experiments of plates at different placement sequence are carried out by using flat bottom die The results show that when 6016 aluminum alloy sheet is placed in the upper layer, the forming quality of self-piercing riveting is better The experimental values of undercut, head height and residual thickness are 0585 mm, 0069 mm and 0212 mm respectively The relative errors between experimental values and simulation values are 362%, 781% and 242% respectively, and the correctness of the finite element simulation is verified In addition, the relationship between undercut and die parameters of self-piercing riveting for steel-aluminum dissimilar materials is analyzed, and it is found that undercut increases with the increase of die width, while it decreases with the increase of die depth

Numerical Simulation and Experimental Study on Self-piercing Riveting of DC03/6016 Dissimilar Sheets

Cushion segment of disc assembly for automobile clutch is taken as research object, a calculation method of forming height for cushion segment is presented based on the analysis of theory of spring back, and it is called reverse trial method. The dimension of forming die for cushion segment is obtained according to reverse trial method, finite element model of bending forming for cushion segment is established. DYNAFORM is used to simulate the spring back of cushion segment, and distribution of stress for forming spring back is analyzed. In addition, forming die is used to verify the forming height by experiment, and the experimental value is 1.55 mm. The results show that the forming height of reverse trial method and simulation are 1.766 mm and 1.63 mm respectively, and the error between reverse trial method and simulation and experiment are 8.34% and 13.94% respectively. Therefore, the correctness of reverse trial method is verified, and it better guides the die design and production of enterprises of cushion segment.

/pdf/research-on-forming-spring-back-of-cushion-segment-for-4y0jcp1uum.pdf

Research on Forming Spring back of Cushion Segment for Automobile Clutch

Intermediate washer of automobile clutch is taken as research object, blanking clearance, radius of corner of punch, blanking speed, blank holder force, counter force and tooth angle of blank holder are selected as influencing factors, length of shear zone is chosen as evaluation index. Orthogonal test with six factors and three levels is established, and Deform-2D is used to simulate fine blanking process of intermediate washer at different combinations of process parameters. Blanking clearance has a significant influence on length of shear zone by variance analysis. The influence sequence of fine blanking process parameters on length of shear zone is blanking clearance, counter force, radius of corner of punch, blank holder force, blanking speed and tooth angle of blank holder. In addition, the optimal combination of process parameters of fine blanking for intermediate washer are as follows: blanking clearance is 8%t, radius of corner of punch is R0.09 mm, blanking speed is 15 mm•s−1, tooth angle of blank holder is 45°, blank holder force is 450 kN and counter force is 150 kN. The simulation value and experimental value of length of shear zone for optimized scheme are 3.945 mm and 3.438 mm respectively, the relative error between simulation value and experimental value is 12.9%. Therefore, it provides an important reference for the actual production of enterprise.

Research on Process Parameters Optimization of Fine Blanking for Intermediate Washer of Clutch Based on Orthogonal Test

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Papers

Experimental and numerical study based on ductile failure for the tri-hub burst of turbocharger turbine

Numerical Simulation and Experimental Study on Self-piercing Riveting of DC03/6016 Dissimilar Sheets

Research on Forming Spring back of Cushion Segment for Automobile Clutch

Research on Process Parameters Optimization of Fine Blanking for Intermediate Washer of Clutch Based on Orthogonal Test