Upsetting of bi-metallic ring billets

Essa, Khamis; Kačmarčik, Igor; Hartley, P.; Plančak, Miroslav; Vilotić, Dragiša

doi:10.1016/j.jmatprotec.2011.11.005

Cited by 28 publications

(22 citation statements)

References 11 publications

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“…The problems of delamination included in Table 1 will not be addressed because these are mainly found when the compression forces are not applied perpendicular to the contact surfaces between the different materials to be joined, as in case of extrusion and rolling [17]. This is not the case in the present investigation.…”

Section: Metal Forming (Extrusion Rolling Upsetting)mentioning

confidence: 93%

“…Other researchers like Essa et al [17] discussed the possibility of producing bimetallic components or prefroms by upsetting, after concluding that some geometries with a good interfacial contact between the center and the ring can be successfully employed as preforms for further processing. A similar conclusion was made by Misirly et al [18] after analyzing the open die forging of bimetallic cylinders with steel rings and brass and pure copper centers, and observing that pure copper prevents the formation of cavities at the center-ring interfaces.…”

Section: Metal Forming (Extrusion Rolling Upsetting)mentioning

confidence: 99%

“…Friction was modelled by means of the law of constant friction. As explained by Essa et al [17], it is not possible to accurately define the frictional conditions prevailing at the center-ring contact interface. But previous research in multi-material upsetting [1,17,18], also lead to the conclusion that variations of the friction factor in the range of 0 to 0.5 do not influence the overall deformation of multi-material components.…”

Section: Finite Element Modelingmentioning

confidence: 99%

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An Experimental and Numerical Analysis of the Compression of Bimetallic Cylinders

et al. 2019

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This paper investigates the upsetting of bimetallic cylinders with an aluminum alloy center and a brass ring. The influence of the center-ring shape factor and type of assembly fit (interference and clearance), and the effect of friction on the compression force and ductile damage are comprehensively analyzed by means of a combined numerical-experimental approach. Results showed that the higher the shape factor, the lower the forces required, whereas the effect of friction is especially important for cylinders with the lowest shape factors. The type of assembly fit does not influence the compression force. The accumulated ductile damage in the compression of bimetallic cylinders is higher than in single-material cylinders, and the higher the shape factor, the lower the damage for the same amount of stroke. The highest values of damaged were found to occur at the middle plane, and typically in the ring. Results also showed that an interference fit was more favorable for preventing fracture of the ring than a clearance fit. Microstructural analysis by scanning electron microscopy revealed a good agreement with the finite element predicted distribution of ductile damage.

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Section: Metal Forming (Extrusion Rolling Upsetting)mentioning

confidence: 93%

Section: Metal Forming (Extrusion Rolling Upsetting)mentioning

confidence: 99%

Section: Finite Element Modelingmentioning

confidence: 99%

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An Experimental and Numerical Analysis of the Compression of Bimetallic Cylinders

et al. 2019

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“…Plančak et al [10] investigated compression of bimetallic components by using C15E and C45E steel for inner and our materials for experimental study and used slab method for analytical approach. Essa et al [11] also expanded their research using the same materials C15E as softer material for core and stronger material C45E as sleeve for upsetting experiments and they investigated interface of these two components using cylindrical samples with different H/D ratios. They analyzed the experimental results with FEM results.…”

Section: Introductionmentioning

confidence: 99%

A numerical study for prediction of forming load and experimental verification of bimetallic disc upsetting

Ayer

2017

Teh. vjesn.

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Original scientific paper Forming of disc samples composed from aluminium and copper in performed study was examined with upsetting procedure. An approach for prediction deformation load of upsetting processes is developed. This study combines the finite element method model, neural network model and upper bound method to simulate and predict the deformation load in upsetting of bimetallic materials. The Finite Element Method (FEM) results were obtained from DEFORM-3D software and they were compared and validated with experiments by taking forming load into consideration. Also, Artificial Neural Network (ANN) model was used to analyze and predict the forming load for different process parameters. The Upper Bound (UB) model was also proposed to estimate the forming load and the results were compared with experiments. It was understood that calculated results were in concordance with experimental results in upsetting of bimetallic hollow discs. Thus, proposed ANN, FEM and UB models provide a valuable insight into the parameters affecting forming load and can be named as useful tools to predict the forming load without the need of any experiments. Keywords: artificial neural network (ANN); bimetallic materials; DEFORM-3D; finite element method (FEM); load analysis; upper bound method (UB); upsetting Numerička analiza za predviđanje nastalog opterećenja i eksperimentalna provjera sabijanja bimetalnog diskaIzvorni znanstveni članak U ovom je istraživanju postupkom sabijanja ispitivano nastajanje pločastih uzoraka sastavljenih od aluminija i bakra. Razvijen je pristup za predviđanje opterećenja koje dovodi do deformacije u postupku sabijanja. U radu se kombinira model metode konačnih elemenata, neuronske mreže i metode gornje granice (upper bound) u svrhu simuliranja i predviđanja opterećenja koje dovodi do deformacije u postupku sabijanja bimetalnih materijala. Rezultati metode konačnih elemenata (FEM) dobiveni su softverom DEFORM-3D te su uspoređeni i provjereni na eksperimentima uzimajući u obzir stvoreno opterećenje. Primijenio se i model Umjetne Neuronske Mreže (Artificial Neural Network -ANN) za analizu i predviđanje nastalog opterećenja kod različitih parametara postupka. Za procjenu nastalog opterećenja predložen je i Upper Bound (UB) model, a rezultati su eksperimentalno uspoređivani. Ustanovilo se da su dobiveni rezultati u skladu s eksperimentalnima u sabijanju bimetalnih šupljih diskova. Prema tome, predloženi ANN, FEM i UB modeli pružaju dragocjen uvid u parametre koji utječu na stvaranje opterećenja i može ih se smatrati korisnim alatima za predviđanje stvaranja opterećenja bez potrebe bilo kakvih eksperimenata. Ključne

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“…There are many commercial programs which allow us to carry out this type of study. Essa et al [4] used Ansys, which is general finite element method software, for the examination of the behavior of bi-metallic components during the cold upsetting process. Luo et al [12] simulated sheet metal flanging and upsetting process by means of the MSC.Marc software.…”

Section: Introductionmentioning

confidence: 99%

Simulation studies on ring upsetting using the Abaqus software

Lisowski

Okoński

Czyżycki

2017

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In this paper, a simulation and an experimental analysis of upsetting a cold ring placed between two rigid plates were conducted. When designing a new process, it is preferable to carry out the simulation studies using FEM, which allow for the prediction of the course and proper selection of process conditions. Due to the complexity of phenomena that occur during plastic formation, it is essential to have a good description of contact phenomena and properties of material in the plastic state. The computer simulation was performed for a specific material -a thick plate of hot-rolled carbon steel with fixed initial dimensions of rings and different values of the coefficient of friction.Keywords: upsetting, friction, FEM simulation Streszczenie W niniejszym artykule przeprowadzono analizę MES spęczania na zimno pierścienia umieszczonego pomiędzy dwoma sztywnymi płytami. Symulację komputerową przeprowadzono dla konkretnego materiału -blachy grubej walcowanej na gorąco ze stali niskowęglowej przy ustalonych wymiarach początkowych pierścieni i różnych wartościach współczynników tarcia. Krzywą wzmocnienia wyznaczono w badaniach własnych. Obliczone wymiary pierścieni oraz wartości sił spęczania porównano z wynikami doświad-czalnymi. Wyraźnie widać silny wpływ warunków tarcia na niejednorodność odkształceń, a zwłaszcza na charakter zmian średnic wewnętrznych. Wykonano badania doświadczalne spęczania z użyciem gładkich i chropowatych kowadeł na sucho i ze smarem, zmieniając w ten sposób warunki tarcia na powierzchniach kontaktowych.Słowa kluczowe: spęczanie, tarcie, analiza MES 168

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Upsetting of bi-metallic ring billets

Cited by 28 publications

References 11 publications

An Experimental and Numerical Analysis of the Compression of Bimetallic Cylinders

An Experimental and Numerical Analysis of the Compression of Bimetallic Cylinders

A numerical study for prediction of forming load and experimental verification of bimetallic disc upsetting

Simulation studies on ring upsetting using the Abaqus software

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