Name: knowledge based cloud fe simulation of sheet metal forming processes
Uploaded: 2016-12-13T12:30:00.000+00:00
Duration: 11 min 5 s
Description: Watch this Scientific Journal Video about Knowledge Based Cloud FE Simulation of Sheet Metal Forming Processes at JoVE.com

The financial support from Innovate UK, Ultra-light Car Bodies (UlCab, reference 101568) and Make it lighter, with less (LightBlank, reference 131818) are gratefully acknowledged. The research leading to these results has received funding from the European Union's Seventh Framework Program (FP7/2007-2013) under grant agreement No. 604240, project title 'An industrial system enabling the use of a patented, lab-proven materials processing technology for Low Cost forming of Lightweight structures for transportation industries (LoCoLite)'. Significant support was also received from the AVIC Centre for Structural Design and Manufacture at Imperial College London, which is funded by Aviation Industry Corporation of China (AVIC).

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The authors have nothing to disclose.

The KBC-FE simulation technique enables advanced simulations to be conducted off site using dedicated modules. It can run functional modules on a cloud environment, that link up nodes from different specializations, to ensure that process simulations are conducted as accurately as possible. The critical aspects in the KBC-FE simulation may involve independency of the FE codes, efficiency of the computation, and accuracy of the functional modules. The realization of each advanced function in a module would rely on the development of a new model and/or a novel experimental technique. For example, the forming limit module is developed based on the new unified forming limit prediction model 11, and the friction tool life prediction module has currently been developed by the implementation of the interactive friction model 20. The KBC-FE simulation technique also offers the function of selective computation, i.e., only the elements fulfilling the selection criteria are selected for further evaluation in the individual modules. For instance, the tool life prediction module automatically selects the elements for which the hard coating tends to breakdown, by ranking the wear rate of all the elements in the 1st forming cycle, thus usually less than 1% of the elements will be selected for further tool life evaluations under multi-cycle loading conditions. In the present research, the tool life prediction after 300 forming cycles can be completed within 5 min.
By conducting the relevant tests and calibrating accordingly, the forming limit model could be applied to forming process simulations to consequently determine the optimal parameters for producing a component from such alloys successfully, and with no incidences of necking. The forming limit prediction model was developed as a cloud module that was independent of the FE software being utilized, and could be applied to any FE software to assess the formability of a material during forming, without complicated subroutines 17. By importing the relevant data into the model, calculations could be carried out to determine whether failure would occur, in regions of the component that the user could specify, saving on computational resources. However, it should be noted that as the stress-strain curves are input into the FE software through a simple look-up table, it may be difficult to fully represent the material properties at various temperatures and strain rates during simulation.&#160;
In the tool life prediction module, the frictional behavior during forming can be predicted by importing the required deformation history data into the verified friction module 20, and then importing the discrete data points calculated by the cloud module for each element back into the FE software. This ensures that the advanced friction module can be used by all FE codes, regardless of their ability to incorporate user-subroutines. Additionally, the module could be run in parallel to further reduce the computation time. The interactive friction/wear model assumed the absence of wear particles during initial sliding, and as a result, it would be reasonable to expect a constant initial value of friction coefficient 0.17 20. Although this model revealed the evolution of friction distribution, the frictional behavior during a forming process is very complicated, and it is difficult to completely integrate the complex frictional behavior from the cloud module into the FE simulation.
As a future technology, the KBC-FE simulation will rely on the development of dedicated and robust internet based FE simulation software packages, which would require a highly profitable, but completely different business model to be established by the software developers. In addition, a dedicated internal network needs to be built within the collaborative parties to ensure data security and the control reliability of the industrial system.

Finite Element (FE) simulations have become a powerful tool for optimizing process parameters in the metal forming industry. The reliability of FE simulation results is dependent on the accuracy of the material definition, input in the form of flow stress data or constitutive equations, and the assignment of the boundary conditions, such as the friction coefficient and the heat transfer coefficient. In the past few years, advanced FE simulations have been developed via the implementation of user-defined subroutines, which have significantly broadened the capability of FE software.
The use of such advanced FE simulations in the design of forming processes for structural components has been investigated by both the aviation and automotive industries, with the intention of producing lightweight structures that reduces operating costs and CO2 emissions. Particular focus has been placed on the replacement of steel components with lower density materials, such as aluminum alloys and magnesium alloys. However, these alloys, especially the stronger variants, offer limited formability at room temperature and thus complex-shaped components cannot be manufactured using the conventional cold stamping process. Therefore, advanced high temperature forming technologies, such as warm aluminum forming 1-4, hot stamping of aluminum alloys 5-9 and hot stamping of high strength steels 10, have been developed over the past decades to enable complex-shaped components to be formed. In general, high temperature forming processes involve significant temperature variations, strain rate and loading path changes 11, which would, for instance, cause inevitable viscoplastic and loading history dependent responses from the work piece materials. These are intrinsic features of high temperature forming processes and may be difficult to represent using conventional FE simulation techniques. Another desirable feature would be the ability to predict the tool life over multiple forming cycles in such processes, since they require low friction characteristics achieved through coatings that degrade with each forming operation. To represent all these features via the implementation of user-defined subroutines would be computationally very expensive. Moreover, the development and implementation of multiple subroutines would require excessive multi-disciplinary knowledge from an engineer conducting the simulations.
In the present work, a novel Knowledge Based Cloud FE (KBC-FE) simulation technique is proposed, based on the application of modules on a cloud computing environment, that enables an efficient and effective method of modeling advanced forming features in conjunction with conventional FE simulations. In this technique, data from the FE software is processed at each cloud module, and then imported back into the FE software in the relevant consistent format, for further processing and analysis. The development of these modules and their implementation in the KBC-FE is detailed.

<table><tbody><tr><td>AA6082-T6</td><td>AMAG</td><td></td><td>Material</td></tr><tr><td>AA5754-H111</td><td>AMAG</td><td></td><td>Material</td></tr><tr><td>1,000 kN high-speed press</td><td>ESH</td><td></td><td>Forming press</td></tr><tr><td>ARGUS</td><td>GOM</td><td></td><td>Optical forming analysis</td></tr><tr><td>PAM-STAMP 2015</td><td>ESI</td><td></td><td>FE simulation software</td></tr><tr><td>Matlab</td><td>MathWorks</td><td></td><td>Numerical calculation software</td></tr><tr><td>Gleeble 3800</td><td>DSI</td><td></td><td>Uniaxial tensile test</td></tr><tr><td>High Temperature Tribometer (THT)</td><td>Anton Paar</td><td></td><td>Friction property test</td></tr><tr><td>NewViewTM 7100</td><td>ZYGO</td><td></td><td>Surface profilometer</td></tr><tr><td>Magnetron sputtering equipment</td><td></td><td></td><td>Coating deposition</td></tr><tr><td>Microhardness tester</td><td>Wolpert Wilson Instruments</td><td></td><td></td></tr><tr><td>Nano-hardness indenter&amp;nbsp;</td><td>MTS</td><td></td><td></td></tr></tbody></table>

knowledge based cloud fe simulation of sheet metal forming processes

The use of Finite Element (FE) simulation software to adequately predict the outcome of sheet metal forming processes is crucial to enhancing the efficiency and lowering the development time of such processes, whilst reducing costs involved in trial-and-error prototyping. Recent focus on the substitution of steel components with aluminum alloy alternatives in the automotive and aerospace sectors has increased the need to simulate the forming behavior of such alloys for ever more complex component geometries. However these alloys, and in particular their high strength variants, exhibit limited formability at room temperature, and high temperature manufacturing technologies have been developed to form them. Consequently, advanced constitutive models are required to reflect the associated temperature and strain rate effects. Simulating such behavior is computationally very expensive using conventional FE simulation techniques.
This paper presents a novel Knowledge Based Cloud FE (KBC-FE) simulation technique that combines advanced material and friction models with conventional FE simulations in an efficient manner thus enhancing the capability of commercial simulation software packages. The application of these methods is demonstrated through two example case studies, namely: the prediction of a material's forming limit under hot stamping conditions, and the tool life prediction under multi-cycle loading conditions.

KBC-FE Simulation for Necking Prediction
In a hot stamping process, the use of a shape-optimized blank will not only save material cost but also help to reduce the presence of defects, such as necking, cracking, and wrinkling. The initial blank shape affects the material flow significantly during forming, and hence a sensible design of the blank shape is critical to the success of the hot stamping process and quality of the final products. To reduce the efforts of trial-and-error experiments to determine the optimal blank geometry, KBC-FE simulation was proven to be a highly efficient and effective method for minimizing the areas with necking. Using this technique, each simulation takes approximately 2 hours, while the parallel cloud module computation for necking prediction is completed within 4 hours.
Figure 4 shows the evolution of the blank shape used in the hot stamping, an example of automotive door inner component. The initial blank shape, adopted from a conventional cold stamping process, was first used in the KBC-FE simulation. Experimental results in Figure 4(a) show that large failure (cracking or necking) areas are visible after the hot stamping. After one iteration of the blank shape optimization, it can be seen in Figure 4(b) that an almost fully successful panel is formed with much less necking, compared to using the initial blank shape. It can be seen that there is still an indication of necking at the pockets in the top right and left corners of the panel. After further optimization in Figure 4(c), the optimized blank shape was finally obtained with no visible necking on the panel. The optimized blank shape determined by the KBC-FE simulation was verified experimentally through hot stamping trials conducted on a fully automated production line offered by a production system manufacturer.
KBC-FE Simulation for Tool Life Prediction
Conventional FE simulations of metal forming processes are performed for a single cycle. However, in a production environment, multiple forming cycles are performed on a given tool, where it is found that an increase in the number of forming cycles results in an increased variation between the formed components. This variation during multi-cycle tool loading is the result of changing surface topography. For example, the multi-cycle loading of forming tools with functional coatings will lead to a coating thickness reduction due to wear. Moreover, the breakdown of the coating will also be influenced by forming parameters, such as the load/pressure, forming speeds, etc. The KBC-FE technique enables the simulation of sheet metal forming processes under multi-cycle loading conditions, which is essential for the in-service life prediction of forming tools with advanced functional coatings.
To investigate the effects of blank holding force on the tool life, blank holding force values of 5, 20, and 50 kN were examined for a constant forming speed of 250 mm/s. Figure 5 shows the remaining tool coating thickness distribution with different blank holding forces after 300 forming cycles. It clearly indicates that the remaining coating thickness decreases with an increase in the blank holding force.
Figure 6 shows the pressure and remaining coating thickness distribution with blank holding forces of 5, 20, and 50 kN, respectively, along the curvilinear distance of the die after 300 forming cycles. Since the region A-B represents the die entrance region during the U-shape bending process, the pressure and the relative wear distance in this region were much higher than other regions of the die. Consequently, the wear of the coating mainly occurred in this area. There are two peak values of coating thickness reduction at 20 kN and 50 kN that correspond to the two peaks under the pressure. Meanwhile, the remaining coating thickness decreases with the increase of blank holding force. The lowest remaining coating thicknesses with blank holding forces of 5, 20, and 50 kN, were 0.905, 0.570, and 0.403 microns, respectively, where the initial coating thickness was 2.1 microns.
<img alt="Figure 1" src="/files/ftp_upload/53957/53957fig1.jpg" /> 
Figure 1: Comparison between experimental and predicted forming limit strains at different temperatures. The forming limit strains increase as temperature rises, at a constant speed of 250 mm/s, or equivalently, a strain rate of 6.26 s-1. <a href="https://www-jove-com.remotexs.ntu.edu.sg/files/ftp_upload/53957/53957fig1large.jpg" target="_blank">Please click here to view a larger version of this figure.</a>
<img alt="Figure 2" src="/files/ftp_upload/53957/53957fig2.jpg" /> 
Figure 2: Schematic chart for knowledge based cloud FE simulation of a sheet metal forming process. Commercial FE simulation software, is used to run the simulation and export the results required for the individual modules. The modules, e.g., formability, heat transfer, post-forming strength (microstructure), tool life prediction, tool design, etc., work simultaneously and independently in the cloud, hence enabling the integration of cutting edge knowledge from multiple sources into FE simulations. <a href="https://www-jove-com.remotexs.ntu.edu.sg/files/ftp_upload/53957/53957fig2large.jpg" target="_blank">Please click here to view a larger version of this figure.</a>
<img alt="Figure 3" src="/files/ftp_upload/53957/53957fig3.jpg" /> 
Figure 3: Geometry of the work piece and tools for the U-shape bending simulation. The tools, i.e., punch, blank holder and die, are modeled using rigid elements. Shell elements are used for the work piece (blank) elements. <a href="https://www-jove-com.remotexs.ntu.edu.sg/files/ftp_upload/53957/53957fig3large.jpg" target="_blank">Please click here to view a larger version of this figure.</a>
<img alt="Figure 4" src="/files/ftp_upload/53957/53957fig4.jpg" /> 
Figure 4: Evolution of blank shape for hot stamping of a door inner panel (displayed in FE simulation). Left: The figures in green frames represent blank shapes at each optimization stage, and the ones in red frames correspond to the blank shape before its optimization. Right: Necking prediction results at each optimization stage. (a) Initial results with large failure (cracking/necking shown in red color), (b) Reduced failure with some necking after first stage of optimization, (c) Final optimized blank shape with no visible necking. <a href="https://www-jove-com.remotexs.ntu.edu.sg/files/ftp_upload/53957/53957fig4large.jpg" target="_blank">Please click here to view a larger version of this figure.</a>
<img alt="Figure 5" src="/files/ftp_upload/53957/53957fig5.jpg" /> 
Figure 5: The remaining coating thickness distribution (displayed in FE simulation) with blank holding forces of: (a) 5 kN, (b) 20 kN, and (c) 50 kN, after 300 forming cycles at a constant stamping speed of 250 mm/s. <a href="https://www-jove-com.remotexs.ntu.edu.sg/files/ftp_upload/53957/53957fig5large.jpg" target="_blank">Please click here to view a larger version of this figure.</a>
<img alt="Figure 6" src="/files/ftp_upload/53957/53957fig6.jpg" /> 
Figure 6: Prediction of contact pressure and remaining coating thickness with blank holding forces of: (a) 5 kN, (b) 20 kN, and (c) 50 kN, along the curvilinear distance of the die at a constant stamping speed of 250 mm/s. <a href="https://www-jove-com.remotexs.ntu.edu.sg/files/ftp_upload/53957/53957fig6large.jpg" target="_blank">Please click here to view a larger version of this figure.</a>

Watch this Scientific Journal Video about Knowledge Based Cloud FE Simulation of Sheet Metal Forming Processes at JoVE.com

Knowledge Based Cloud FE Simulation of Sheet Metal Forming Processes

The following paper presents a novel FE simulation technique (KBC-FE), which reduces computational cost by performing simulations on a cloud computing environment, through the application of individual modules. Moreover, it establishes a seamless collaborative network between world leading scientists, enabling the integration of cutting edge knowledge modules into FE simulations.

The use of Finite Element (FE) simulation software to adequately predict the outcome of sheet metal forming processes is crucial to enhancing the ...

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12.1K Views.  Imperial College London. The following paper presents a novel FE simulation technique (KBC-FE), which reduces computational cost by performing simulations on a cloud computing environment, through the application of individual modules. Moreover, it establishes a seamless collaborative network between world leading scientists, enabling the integration of cutting edge knowledge modules into FE simulations.

Video: Knowledge Based Cloud FE Simulation of Sheet Metal Forming Processes

Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting

One of the typical methods to manufacture 3D lattice metals is the direct-metal additive manufacturing (AM) process such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM). In spite of its potential processing capability, the direct AM method has several disadvantages such as high cost, poor surface finish of final products, limitation in material selection, high thermal stress, and anisotropic properties of parts. We propose a cost-effective method to manufacture 3D lattice metals. The objective of this study is to provide a detailed protocol on fabrication of 3D lattice metals having a complex shape and a thin wall thickness; e.g., octet truss made of Al and Cu alloys having a unit cell length of 5 mm and a cell wall thickness of 0.5 mm. An overall experimental procedure is divided into eight sections: (a) 3D printing of sacrificial patterns (b) melt-out of support materials (c) removal of residue of support materials (d) pattern assembly (e) investment (f) burn-out of sacrificial patterns (g) centrifugal casting (h) post-processing for final products. The suggested indirect AM technique provides the potential to manufacture ultra-lightweight lattice metals; e.g., lattice structures with Al alloys. It appears that the process parameters should be properly controlled depending on materials and lattice geometry, observing the final products of octet truss metals by the indirect AM technique.

An indirect additive manufacturing method combining a 3D printing of polymers with a centrifugal casting is outlined for manufacturing 3D octet truss metals (Al and Cu alloys) having a unit cell length of 5 mm with a wall thickness of 0.5 mm.

One of the typical methods to manufacture 3D lattice metals is the direct-metal additive manufacturing (AM) process such as Selective Laser Melting (SLM) ...

Experimental Methods for Investigation of Shape Memory Based Elastocaloric Cooling Processes and Model Validation

Shape Memory Alloys (SMA) using elastocaloric cooling processes have the potential to be an environmentally friendly alternative to the conventional vapor compression based cooling process. Nickel-Titanium (Ni-Ti) based alloy systems, especially, show large elastocaloric effects. Furthermore, exhibit large latent heats which is a necessary material property for the development of an efficient solid-state based cooling process. A scientific test rig has been designed to investigate these processes and the elastocaloric effects in SMAs. The realized test rig enables independent control of an SMA&#39;s mechanical loading and unloading cycles, as well as conductive heat transfer between SMA cooling elements and a heat source/sink. The test rig is equipped with a comprehensive monitoring system capable of synchronized measurements of mechanical and thermal parameters. In addition to determining the process-dependent mechanical work, the system also enables measurement of thermal caloric aspects of the elastocaloric cooling effect through use of a high-performance infrared camera. This combination is of particular interest, because it allows illustrations of localization and rate effects &#8212; both important for efficient heat transfer from the medium to be cooled.
The work presented describes an experimental method to identify elastocaloric material properties in different materials and sample geometries. Furthermore, the test rig is used to investigate different cooling process variations. The introduced analysis methods enable a differentiated consideration of material, process and related boundary condition influences on the process efficiency. The comparison of the experimental data with the simulation results (of a thermomechanically coupled finite element model) allows for better understanding of the underlying physics of the elastocaloric effect. In addition, the experimental results, as well as the findings based on the simulation results, are used to improve the material properties.

Experimental methods for investigation of solid state cooling processes and characterization of elastocaloric material properties of Shape Memory Alloys (SMA) are presented. A custom-built test rig has been designed for controlling and comprehensive monitoring of elastocaloric cooling processes. Furthermore, it provides a validation platform for thermomechanically coupled modeling approaches.

Shape Memory Alloys (SMA) using elastocaloric cooling processes have the potential to be an environmentally friendly alternative to the conventional vapor ...

Experimental Procedure for Warm Spinning of Cast Aluminum Components

High performance, cast aluminum automotive wheels are increasingly being incrementally formed via flow forming/metal spinning at elevated temperatures to improve material properties. With a wide array of processing parameters which can affect both the shape attained and resulting material properties, this type of processing is notoriously difficult to commission. A simplified, light-duty version of the process has been designed and implemented for full-size automotive wheels. The apparatus is intended to assist in understanding the deformation mechanisms and the material response to this type of processing. An experimental protocol has been developed to prepare for, and subsequently perform forming trials and is described for as-cast A356 wheel blanks. The thermal profile attained, along with instrumentation details are provided. Similitude with full-scale forming operations which impart significantly more deformation at faster rates is discussed.

An experimental protocol for instrumented warm rotary forming of cast aluminum alloys employing a bespoke industrially scaled apparatus is presented. Experimental considerations including thermal and mechanical effects are discussed, as well as similitude with full-scale processing of automotive wheels.

High performance, cast aluminum automotive wheels are increasingly being incrementally formed via flow forming/metal spinning at elevated temperatures to ...

A Novel Biaxial Testing Apparatus for the Determination of Forming Limit under Hot Stamping Conditions

The hot stamping and cold die quenching process is increasingly used to form complex shaped structural components of sheet metals. Conventional experimental approaches, such as out-of-plane and in-plane tests, are not applicable to the determination of forming limits when heating and rapid cooling processes are introduced prior to forming for tests conducted under hot stamping conditions. A novel in-plane biaxial testing system was designed and used for the determination of forming limits of sheet metals at various strain paths, temperatures, and strain rates after heating and cooling processes in a resistance heating uniaxial testing machine. The core part of the biaxial testing system is a biaxial apparatus, which transfers a uniaxial force provided by the uniaxial testing machine to a biaxial force. One type of cruciform specimen was designed and verified for the formability test of aluminum alloy 6082 using the proposed biaxial testing system. The digital image correlation (DIC) system with a high-speed camera was used for taking strain measurements of a specimen during a deformation. The aim of proposing this biaxial testing system is to enable the forming limits of an alloy to be determined at various temperatures and strain rates under hot stamping conditions.

This protocol proposes a novel biaxial testing system used on a resistance heating uniaxial tensile test machine in order to determine the forming limit diagram (FLD) of sheet metals under hot stamping conditions.

The hot stamping and cold die quenching process is increasingly used to form complex shaped structural components of sheet metals. Conventional ...

A Coupled Experiment-finite Element Modeling Methodology for Assessing High Strain Rate Mechanical Response of Soft Biomaterials

This study offers a combined experimental and finite element (FE) simulation approach for examining the mechanical behavior of soft biomaterials (e.g. brain, liver, tendon, fat, etc.) when exposed to high strain rates. This study utilized a Split-Hopkinson Pressure Bar (SHPB) to generate strain rates of 100-1,500 sec-1. The SHPB employed a striker bar consisting of a viscoelastic material (polycarbonate). A sample of the biomaterial was obtained shortly postmortem and prepared for SHPB testing. The specimen was interposed between the incident and transmitted bars, and the pneumatic components of the SHPB were activated to drive the striker bar toward the incident bar. The resulting impact generated a compressive stress wave (i.e. incident wave) that traveled through the incident bar. When the compressive stress wave reached the end of the incident bar, a portion continued forward through the sample and transmitted bar (i.e. transmitted wave) while another portion reversed through the incident bar as a tensile wave (i.e. reflected wave). These waves were measured using strain gages mounted on the incident and transmitted bars. The true stress-strain behavior of the sample was determined from equations based on wave propagation and dynamic force equilibrium. The experimental stress-strain response was three dimensional in nature because the specimen bulged. As such, the hydrostatic stress (first invariant) was used to generate the stress-strain response. In order to extract the uniaxial (one-dimensional) mechanical response of the tissue, an iterative coupled optimization was performed using experimental results and Finite Element Analysis (FEA), which contained an Internal State Variable (ISV) material model used for the tissue. The ISV material model used in the FE simulations of the experimental setup was iteratively calibrated (i.e. optimized) to the experimental data such that the experiment and FEA strain gage values and first invariant of stresses were in good agreement.

The current study prescribes a coupled experiment-finite element simulation methodology to obtain the uniaxial dynamic mechanical response of soft biomaterials (brain, liver, tendon, fat, etc.). The multiaxial experimental results that arose because of specimen bulging obtained from Split-Hopkinson Pressure Bar testing were rendered to a uniaxial true stress-strain behavior when simulated through iterative optimization of the finite element analysis of the biomaterial.

This study offers a combined experimental and finite element (FE) simulation approach for examining the mechanical behavior of soft biomaterials (e.g. ...

Bioengineering

Structural Design and Manufacturing of a Cruiser Class Solar Vehicle

Cruisers are multi-occupant solar vehicles that are conceived to compete in long-range (over 3,000 km) solar races based on the best compromise between the energy consumption and the payload. They must comply to the race&#39;s rules regarding the overall dimensions, the solar panel size, functionality, and safety and structural requirements, while the shape, the materials, the powertrain, and the mechanics are considered at the discretion of the designer. In this work, the most relevant aspects of the structural design process of a full-carbon fiber-reinforced plastic solar vehicle are detailed. In particular, the protocols used for the design of the lamination sequence of the chassis, the leaf springs structural analysis, and the crash test numerical simulation of the vehicle, including the safety cage, are described. The complexity of the design methodology of fiber-reinforced composite structures is compensated by the possibility of tailoring their mechanical characteristics and optimizing the overall weight of the car.

In this work, several aspects related to the structural design process of a full-carbon fiber-reinforced plastic solar vehicle are detailed, focusing on the monocoque chassis, the leaf springs, and the vehicle as a whole during a crash test.

Cruisers are multi-occupant solar vehicles that are conceived to compete in long-range (over 3,000 km) solar races based on the best compromise between ...

Finite Element Modeling for the Simulation of the Quasi-Static Compression of Corrugated Tapered Tubes

In this study, the quasi-static compression performance of tapered tubes was investigated using finite element simulations. Previous studies have shown that a thickness gradient can reduce the initial peak force and that lateral corrugation can increase the energy absorption performance. Therefore, two kinds of lateral corrugated tapered tubes with variable thicknesses were designed, and their deformation patterns, load displacement curves, and energy absorption performance were analyzed. The results showed that when the thickness variation factor (k) was 0.9, 1.2, and 1.5, the deformation mode of the single corrugated tapered tube (ST) changed from transverse expansion and contraction to axial progressive folding. In addition, the thickness gradient design improved the energy absorption performance of the ST. The energy absorption (EA) and specific energy absorption (SEA) of the model with k = 1.5 increased by 53.6% and 52.4%, respectively, compared with the ST model with k = 0. The EA and SEA of the double corrugated tapered tube (DT) increased by 373% and 95.7%, respectively, compared with the conical tube. The increase in the k value resulted in a significant decrease in the peak crushing force of the tubes and an increase in the crushing force efficiency.

This protocol describes the study of the quasi-static compression performance of corrugated tapered tubes using finite element simulations. The influence of the thickness gradient on the compression performance was investigated. The results show that proper thickness gradient design can change the deformation mode and significantly improve the energy absorption performance of the tubes.

In this study, the quasi-static compression performance of tapered tubes was investigated using finite element simulations. Previous studies have shown ...

A Virtual Simulation Experiment of Mechanics: Material Deformation and Failure Based on Scanning Electron Microscopy

This work presents a set of comprehensive virtual experiments to detect material deformation and failure. The most commonly used pieces of equipment in mechanics and material disciplines, such as a metallographic cutting machine and a high-temperature universal creep testing machine, are integrated into a web-based system to provide different experimental services to users in an immersive and interactive learning environment. The protocol in this work is divided into five subsections, namely, the preparation of the materials, molding the specimen, specimen characterization, specimen loading, nanoindenter installation, and SEM in situ experiments, and this protocol aims to provide an opportunity for users regarding the recognition of different equipment and the corresponding operations, as well as the enhancement of laboratory awareness, etc., using a virtual simulation approach. To provide clear guidance for the experiment, the system highlights the equipment/specimen to be used in the next step and marks the pathway that leads to the equipment with a conspicuous arrow. To mimic the hands-on experiment as closely as possible, we designed and developed a three-dimensional laboratory room, equipment, operations, and experimental procedures. Moreover, the virtual system also considers interactive exercises and registration before using chemicals during the experiment. Incorrect operations are also allowed, resulting in a warning message informing the user. The system can provide interactive and visualized experiments to users at different levels.

This work presents a three-dimensional virtual simulation experiment for material deformation and failure that provides visualized experimental processes. Through a set of experiments, users can become familiar with the equipment and learn the operations in an immersive and interactive learning environment.

This work presents a set of comprehensive virtual experiments to detect material deformation and failure. The most commonly used pieces of equipment in ...

A Comprehensive Approach to Investigate RMU Temperature Rise Problem

Comparative Study of Simulation of Temperature Rise in Ring Main Unit

The Ring Main Unit (RMU) is a critical device in power distribution systems used for connecting and distributing electricity. However, due to its compact internal structure and high current load, heat dissipation issues are particularly prominent. To address this problem, this study innovatively proposes a simplified RMU model, employing finite element simulation methods to accurately solve for the ohmic losses of conductors under actual operating conditions and obtain ohmic loss data for various components. This is the first in-depth investigation of the RMU's temperature rise problem using such a comprehensive approach. Subsequently, the temperature field was solved using two different temperature field analysis modules, with a detailed comparison and analysis of the simulation results to identify similarities, differences, and trends in temperature distribution. The results indicate that the temperature field solution model, which considers convective heat transfer, is more accurate and aligns with actual operating conditions. This research provides an innovative approach and practical solutions for the design and optimization of RMUs. Future research can further explore multiphysics coupling analysis methods to address structural design and mandatory validation issues for high and ultra-high voltage RMUs and other electrical equipment, thereby providing important insights for engineering design.

Author Spotlight: Simulation and Analysis of the Temperature Rise of Ring Main Unit Equipment

This paper addresses the temperature rise problem of the ring main unit by establishing a simplified model and conducting a comparative analysis in two temperature field-solving modules.

The Ring Main Unit (RMU) is a critical device in power distribution systems used for connecting and distributing electricity. However, due to its compact ...

Surrogate Model Development for Digital Experiments in Welding

The manufacturing industry heavily relies on welding processes to join materials, forming integral components across various sectors. Many aspects will influence the quality of the weld and finally affect the structure integrity of the weldment. Welding-induced residual stress, a consequence of the thermal cycling inherent in these processes, significantly impacts the structural integrity and performance of fabricated components. Understanding and predicting this residual stress is crucial for enhancing the reliability and durability of welded structures. However, quickly assessing a welding setup in digital experiments presents significant challenges, as a traditional simulation may be time-consuming. This research outlines the application of a workflow to construct an artificial neural network-based surrogate model to predict welding-induced residual stress. The model is built using data automatically generated from finite element simulations through Python scripts based on macro functions. Unlike traditional methods that rely on manual preprocessing and finite element simulations, this approach significantly reduces the time and effort required for simulation setup and data extraction, enhancing overall efficiency. By ensuring that all simulation steps are performed consistently through macro functions, the method eliminates human-induced variability, leading to improved reproducibility. Furthermore, the automation of data generation makes it possible to create extensive datasets necessary for training machine learning models, overcoming the limitations of labor-intensive traditional techniques. The workflow contains four main steps: build a standard weld finite element simulation and validate the finite element simulation results against experimental data; develop scripts for large dataset generation using a macro function that records the preprocessing and postprocessing steps of the finite element simulation; use the scripts to generate the required data; develop surrogate models and test their performance. The artificial neural network demonstrated high accuracy in predicting stress levels, closely aligning with simulation results on the test dataset and a relative root mean square error of 0.0024.

This protocol outlines a general workflow for constructing an artificial neural network for welding simulation using datasets generated automatically through Python scripts with macro functions. The workflow is validated against a benchmark case involving single-pass, straight-line welding. The surrogate model's predictive accuracy shows a strong agreement with finite element simulations.

The manufacturing industry heavily relies on welding processes to join materials, forming integral components across various sectors. Many aspects will ...

Knowledge Based Cloud FE Simulation of Sheet Metal Forming Processes

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