| 1. |
- Pilthammar, Johan, 1987-
(författare)
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Towards Virtual Tryout and Digital Twins : Enhanced Modeling of Elastic Dies, Sheet Materials, and Friction in Sheet Metal Forming
- 2020
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Competition and complexity in the global car market are continuously increasing. To gain an edge in the market while making a profit, each competitor in the market needs a strong focus on technology development. Such a focus will increase the value of the product for the customers. On top of the challenges of developing the technical content of the cars, it is equally important to develop the manufacturing processes. This will enable the production of technically advanced and attractive products at a competitive cost.An important manufacturing process within the automotive industry, and the focus of this PhD thesis, is sheet metal forming (SMF). The SMF process has been simulated for the past few decades with finite element (FE) simulations, whereby factors such as shape, strains, thickness, springback, risk of failure, and wrinkles can be predicted. A factor that most SMF simulations do not currently include is die and press elasticity, limiting the reliability of SMF simulations for virtual die tryout and digital twins. This factor is instead handled manually during the die tryout, which is time-consuming and expensive.The importance of accurately representing press and die elasticity in SMF simulations is the focus of this research project. The objective is to achieve virtual tryout and production support through SMF simulations that consider elastic die and press deformations. Accurate simulations of die tryout, or dies in running production, are found to be impossible without the inclusion of reliable representations of elastic dies and presses.Accurate CAD models of stamping dies are common. Strategies are presented for how to include them in SMF simulations models that are easy to set up and fast to solve. Full representations of presses are rarer. Methods for measuring and inverse modeling the elasticity of presses are therefore presented together with an overview from the literature of other methods. A unified method that is reliable and cost-efficient for the stamping industry is of high interest.SMF simulations with elastic dies will only yield accurate predictions if reliable models of sheet materials and lubrication systems are included. Friction in particular is highly dependent on die deformations since contact pressure is an important parameter in determining the friction level. Reliable models for both friction and sheet materials are dependent on accurate experimental data and characterization methods.Including elastic die and press deformations in SMF simulations, together with reliable representations of friction and sheet materials, has immense potential to reduce the lead time of stamping dies. The simulation methods that include elasticity will also be vital for more accurate digital twins of press lines.
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| 2. |
- Shahid, Sharlin, 1992-, et al.
(författare)
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Simplified Characterization of Anisotropic Yield Criteria for an Injection-Molded Polymer Material
- 2023
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Ingår i: Polymers. - : MDPI. - 2073-4360. ; 15:23
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Tidskriftsartikel (refereegranskat)abstract
- Injection-molded polyethylene plates exhibit highly anisotropic mechanical behavior due to, e.g., the uneven orientation of the polymer chains during the molding process and the differential cooling, especially in the thickness direction. Elastoplastic finite element modeling of these plates in particular is used with isotropic yield criteria like von Mises, trading off accuracy in favor of simpler constitutive characterization and faster solution. This article studies three different anisotropic yield criteria, namely, Hill 1948, Barlat Yld91, and Barlat Yld2004-18P, for the finite element modeling of low-density polyethylene (LDPE) at large uniaxial tensile deformation and compares the accuracy and computation time with von Mises. A simplified calibration technique is investigated to identify the constitutive parameters of the studied Barlat group yield criteria. The calibration process is simplified in the sense that only uniaxial tensile tests with digital image correlation measurements are used for the calibration of all the yield criteria studied in this article, although a standard calibration procedure for the Barlat group yield criteria requires additional material testing using more demanding test setups. It is concluded that both Barlat Yld91 and Barlat Yld2004-18P yield criteria can be calibrated with only a few tensile tests and still capture anisotropy in deformation–stress–strain at different levels of accuracy. © 2023 by the authors.
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| 3. |
- Shahmardani, Mahdieh, et al.
(författare)
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Numerical simulation of buckling and post-buckling behavior of a central notched thin aluminum foil with nonlinearity in consideration
- 2020
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Ingår i: Metals. - : MDPI AG. - 2075-4701. ; 10:5
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Tidskriftsartikel (refereegranskat)abstract
- In thin notched sheets under tensile loading, wrinkling appears on the sheet surface, specifically around the cracked area. This is due to local buckling and compression stresses near the crack surfaces. This study aims to numerically study the buckling behavior of a thin sheet with a central crack under tension. A numerical model of a notched sheet under tensile loading is developed using the finite element method, which considers both material and geometrical nonlinearity. To overcome the convergence problem caused by the small thickness-to-length/width ratio and to stimulate the buckling, an imperfection is defined as a small perturbation in the numerical model. Both elastic and elasto-plastic behavior are applied, and the influence of them is studied on the critical buckling stress and the post-buckling behavior of the notched sheet. Numerical results for both elastic and elasto-plastic behavior reflect that very small perturbations need more energy for the activation of buckling mode, and a higher buckling mode is predominant. The influences of different parameters, including Poisson’s ratio, yield limit, crack length-to-sheet-width ratio, and the sheet aspect ratio are also evaluated with a focus on the critical buckling stress and the buckling mode shape. With increase in Poisson’s ratio. First, the critical buckling stress reduces and then remains constant. A higher yield limit results in increases in the critical buckling stress, and no change in the buckling mode shape while adopting various crack length-to-sheet-width ratios, and the sheet aspect ratio changes the buckling mode shape.
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| 4. |
- Ståhle, Per, et al.
(författare)
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On buckling and fracture of thin elastic-plastic foils
- 2020
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Ingår i: 1ST VIRTUAL EUROPEAN CONFERENCE ON FRACTURE - VECF1. - : ELSEVIER. ; , s. 2065-2071
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Konferensbidrag (refereegranskat)abstract
- The interaction of simultaneous fracture and buckling constitutes problems at manufacturing and handling of thin foils. Buckling occurs as an additional event that complicates the prediction of the critical load that may lead to fracture. For most sufficiently thin foils the plastic slip occurs through the foil thickness which leads to reduction of the cross section width until the foil fails. The process leads to a necking type of deformation which confines itself to a narrow region that extends ahead of the crack tip. The width of the region is close to the foil thickness. At failure the width of the necking region is twice the foil thickness. In the present investigation the crack is assumed to be small compared to the foil geometry and the foil is assumed to be small compared with the crack length. Because of the latter the necking type of plastic region is modelled as a cohesive zone. Since the fracture toughness is not involved in the failure the only two relevant length parameters are crack length and foil thickness. The material model is defined by the elastic modulus, Poisson's ratio and yield stress. The remote load at buckling and at failure is determined and given on dimensionless form, which leaves Poisson's ratio and the ratio of buckling stress versus failure stress as the only free parameters. Two scales of yielding, the load at the ASTM-limit for linear fracture mechanics and twice that load, including the purely elastic result are investigated. Poisson's ratio is varied in the interval from -0.9 to 0.5 for the elastic case and from -0.6 to 0.5 for the plastic cases. The lower theoretical limit -1 for Poisson's ratio was not obtained because of numerical difficulties. The results rules out the possibility of failure before buckling for any reasonable construction material. (C) 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd4.0) Peer-review under responsibility of the European Structural Integrity Society (ESIS) ExCo
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| 5. |
- Ståhle, Per, et al.
(författare)
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On buckling and fracture of thin elastic-plastic foils : Part of special issue: 1st Virtual European Conference on Fracture - VECF1
- 2020
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Ingår i: Procedia Structural Integrity. - : Elsevier BV. - 2452-3216. ; 28, s. 2065-2071
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Konferensbidrag (refereegranskat)abstract
- The interaction of simultaneous fracture and buckling constitutes problems at manufacturing and handling of thin foils. Buckling occurs as an additional event that complicates the prediction of the critical load that may lead to fracture. For most sufficiently thin foils the plastic slip occurs through the foil thickness which leads to reduction of the cross section width until the foil fails. The process leads to a necking type of deformation which confines itself to a narrow region that extends ahead of the crack tip. The width of the region is close to the foil thickness. At failure the width of the necking region is twice the foil thickness. In the present investigation the crack is assumed to be small compared to the foil geometry and the foil is assumed to be small compared with the crack length. Because of the latter the necking type of plastic region is modelled as a cohesive zone. Since the fracture toughness is not involved in the failure the only two relevant length parameters are crack length and foil thickness. The material model is defined by the elastic modulus, Poisson's ratio and yield stress. The remote load at buckling and at failure is determined and given on dimensionless form, which leaves Poisson's ratio and the ratio of buckling stress versus failure stress as the only free parameters. Two scales of yielding, the load at the ASTM-limit for linear fracture mechanics and twice that load, including the purely elastic result are investigated. Poisson's ratio is varied in the interval from -0.9 to 0.5 for the elastic case and from -0.6 to 0.5 for the plastic cases. The lower theoretical limit -1 for Poisson's ratio was not obtained because of numerical difficulties. The results rules out the possibility of failure before buckling for any reasonable construction material.
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| 6. |
- Wang, Xueliang, 1993-, et al.
(författare)
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Numerical evaluation of rotordynamic coefficients for compliant foil gas seal
- 2020
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Ingår i: Applied Sciences. - : MDPI AG. - 2076-3417. ; 10:11
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Tidskriftsartikel (refereegranskat)abstract
- Compliant foil gas seal is one of the advanced cylindrical gas seal technologies and can be commonly used in the secondary flow system of an aero-engine. It can enhance the dynamic stability of the aero-engine by meeting the steady requirements of the aero-engine seal system. To evaluate the performance of compliant foil gas seal, the steady performance of the gas seal is firstly analyzed to predict the sealing efficiency and obtain the pressure distribution of the gas seal in the compressible flow field. Then, the effects of the operating parameters on the rotordynamic coefficients are analyzed using the finite differential method. It can be used to predict the operation performance of the aero-engine and prepare for the optimization and test rig of compliant foil gas seal on the T-shaped groove. © 2020 by the authors.
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