• Transactions of Materials Processing
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• v.24 no.4
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• pp.227-233
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• 2015

In this paper, the effect of flow stress, friction, temperature, and velocity on finite element predictions of metal flow lines after cylindrical upsetting is presented. An actual three-stage hot forging process involving an upsetting step is utilized and experimental metal flow lines are measured to study the effect of the various process variables. It was found that temperature and velocity for reasonable values of friction have little influence on metal flow lines especially those located deep within the cylinder but that flow stress has a direct influence on the flow lines. It was shown that a pure power law material model cannot reflect the real flow stress of hot material because it underestimates the flow stress especially around the dead-metal zone for the upsetting of a cylindrical specimen. It is thus recommended that a proper lower limit of flow stress be assumed to alleviate this issue.

• Transactions of Materials Processing
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• v.24 no.4
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• pp.234-240
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• 2015

Multi-pass shape drawing is very important to produce steel profiles in round samples. In the current study, a process design system is developed for a multi-pass shape drawing. In general, the number of passes for a multi-pass shape drawing is 2 to 3 when the reduction ratio, drawing stress, and productivity are considered. Therefore, calculating the drawing stress and designing the intermediated die shapes are very important. In order to calculate the drawing stress, a shape drawing load prediction method is proposed using a general axisymmetric drawing load prediction model. An intermediate die shape design method is proposed using the initial and the final product shapes. Based on this analysis, a process design system is developed for multi-pass shape drawing for steel profiles. The system works with AutoCAD. The system was applied to design a shape drawing of a spline.

• Transactions of Materials Processing
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• v.20 no.2
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• pp.132-139
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• 2011

Three dimensional simulations were performed for the deformation of a slab in a roller hearth type slab reheating furnace. The main objective of this study was to examine the deformation pattern of the slab due to the shadow effect, i.e., the temperature difference between the upper and lower slab surfaces, in particular, the variations of displacement and effective stress in the vertical direction. A commercially available FE code, ANSYS Workbench $12.1^{TM}$, was used in a fully coupled thermo-elasticity analysis. Several cases with different slab surface temperatures were selected for the simulations. For the sake of simplicity, the temperature environment inside the furnace was assumed to be homogeneous for the upper and lower faces of the slab. Two cases of with different slab width were selected as model geometry. The deformation patterns were computed and explained in terms of periodicity and symmetry. The results indicated that the shadow effect leads to a significant displacement in the vertical direction and, thereby, is one of the main reasons for the separation of the slab and its supports. These simulations also predicted that the deformation is more severe along the transverse direction than along the longitudinal direction.

• Transactions of Materials Processing
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• v.20 no.3
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• pp.243-249
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• 2011

In this study, an approach designed to compute high temperature friction coefficients for SCM 435 steel through a pilot hot rolling test and a finite element analysis, is proposed. Single pass pilot hot flat rolling tests with reduction ratios varying from 20 to 40% were carried out at temperatures ranging from 900 to $1200^{\circ}C$. In the proposed approach, the friction coefficient is calculated by comparing the measured strip spread and the roll force with the simulation results. This study showed that the temperature and reduction ratio had a significant influence on the friction coefficient. As both material temperature and reduction ratio become higher, the friction coefficient increases monotonically. This finding is not in agreement with the Ekelund model, which is widely used in the analysis of the hot rolling process. In the present work, the friction coefficient at a reduction ratio of 40% was found to be 1.2 times greater than that at a reduction of 30%. This higher friction coefficient means that an increment of the roll thrust force is expected at the next stand. Therefore, a roll pass designer must understand this phenomenon in order to adjust the reduction ratio at the stands while keeping the driving power, the roll housing structure and the work roll strength within the allowable range.

• Transactions of Materials Processing
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• v.23 no.6
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• pp.376-379
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• 2014

During roll forming a sheet metal is continuously and progressively formed into a product of the required cross-section and longitudinal shape. An example product is a circular tube with a required diameter, wall-thickness and straightness. Roll forming occurs by passing the sheet through a series of forming rolls that are arranged in tandem. Each pair of forming rolls in the roll forming line plays a particular role in obtaining the required cross-section and longitudinal shape in the product. In recent years, that process is often applied to car body parts by automotive industries. In the current study, an optimal model design and proper roll-pass sequences as well as the number of forming rolls and bending angles were used to produce a sill side. The effects of the process parameters on the final shape formed by roll forming defects were evaluated.

• Transactions of Materials Processing
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• v.13 no.3
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• pp.216-224
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• 2004

In this study, we have developed a new UV$({\lambda}=355nm)$ laser micromachining technology by direct ablation method without masks. This technology allows that 3D micro parts can be fabricated rapidly and efficiently with a low price. And it has a benefit of reducing fabricating process simply. Due to micro parts' fabrication, such technologies need the control of XYZ stages with high precision, the design of optical devices to maintain micron spot sizes of laser beam and the control technology of laser focus. The developed laser manufacturing process for laser micromachining is that, after extracting coordinates of shape data from CAD model data, a beam path considering manufacturing features of laser beam is created by using genetic algorithm. This generated manufacturing process is sent to stage controller. In order to improve the surface quality of micro parts, we have carried out experiments on iteration manufacturing and beam step-over by using a minimum focus size. Moreover, we have fabricated a micro-channel through the developed laser micromachining technology and verified it through the results.

• Structural Engineering and Mechanics
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• v.56 no.1
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• pp.49-56
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• 2015

Dynamic compaction (DC) is a useful method for improvement of granular soils. The method is based on falling a tamper (weighting 5 to 40 ton) from the height of 15 to 30 meters on loose soil that results in stress distribution, vibration of soil particles and desirable compaction of the soil. Propagation of the waves during tamping affects adjacent structures and causes structural damage or loss of performance. Therefore, determination of the safe or critical distance from tamping point to prevent structural hazards is necessary. According to FHWA, the critical distance is defined as the limit of a particle velocity of 76 mm/s. In present study, the ABAQUS software was used for numerical modeling of DC process and determination of the safe distance based on particle velocity criterion. Different variables like alluvium depth, relative density, and impact energy were considered in finite element modeling. It was concluded that for alluvium depths less than 10 m, reflection of the body waves from lower boundaries back to the soil and resonance phenomenon increases the critical distance. However, the critical distance decreases for alluvium depths more than 10 m. Moreover, it was observed that relative density of the alluvium does not significantly influence the critical distance value.

• Structural Engineering and Mechanics
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• v.35 no.2
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• pp.241-256
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• 2010

The interaction between steel tube and concrete core is the key issue for understanding the behavior of concrete-filled steel tube columns (CFTs). This study investigates the force transfer by natural bond or by mechanical shear connectors and the interaction between the steel tube and the concrete core under three types of loading. Two and three-dimensional nonlinear finite element models are developed to study the force transfer between steel tube and concrete core. The nonlinear finite element program ABAQUS is used. Material and geometric nonlinearities of concrete and steel are considered in the analysis. The damage plasticity model provided by ABAQUS is used to simulate the concrete material behavior. Comparisons between the finite element analyses and own experimental results are made to verify the finite element models. A good agreement is observed between the numerical and experimental results. Parametric studies using the numerical models are performed to investigate the effects of diameterto-thickness ratio, uniaxial compressive strength of concrete, length of shear connectors, and the tensile strength of shear connectors.

• Structural Engineering and Mechanics
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• v.45 no.1
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• pp.129-144
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• 2013

Load-carrying capacity of combined members consisted of inner and sleeved tubes subjected to axial compression was investigated in this paper. Considering the initial bending of the inner tube and perfect elasto-plasticity material model, structural behavior of the sleeved member was analyzed by theoretic deduction, which could be divided into three states: the elastic inner tube contacts the outer sleeved tube, only the inner tube becomes plastic and both the inner and outer sleeved tubes become plastic. Curves between axial compressive loads and lateral displacements of the middle sections of the inner tubes were obtained. Then four sleeved members were analyzed through FEM, and the numerical results were consistent with the theoretic formulas. Finally, experiments of full-scale sleeved members were performed. The results obtained from the theoretical analysis were verified against experimental results. The compressive load-lateral displacement curves from the theoretical analysis and the tests are similar and well indicate the point when the inner tube contacts the sleeved tube. Load-carrying capacity of the inner tube can be improved due to the sleeved tube. This paper provides theoretical basis for application of the sleeved members in reinforcement engineering.

• Structural Engineering and Mechanics
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• v.25 no.1
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• pp.107-126
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• 2007

The problem related to the computation of bounds on plastic deformations for structures in plastic shakedown condition (alternating plasticity) is studied. In particular, reference is made to structures discretized by finite elements constituted by elastic perfectly plastic material and subjected to a special combination of fixed and cyclic loads. The load history is known during the steady-state phase, but it is unknown during the previous transient phase; so, as a consequence, it is not possible to know the complete elastic plastic structural response. The interest is therefore focused on the computation of bounds on suitable measures of the plastic strain which characterizes just the first transient phase of the structural response, whatever the real load history is applied. A suitable structural model is introduced, useful to describe the elastic plastic behaviour of the structure in the relevant shakedown conditions. A special bounding theorem based on a perturbation method is proposed and proved. Such theorem allows us to compute bounds on any chosen measure of the relevant plastic deformation occurring at the end of the transient phase for the structure in plastic shakedown; it represents a generalization of analogous bounding theorems related to the elastic shakedown. Some numerical applications devoted to a plane steel structure are effected and discussed.