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Constitutive model validity evaluation for MT 2.0 applications MT 2.0 应用的构造模型有效性评估
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-203
Amar Peshave
Abstract. This paper demonstrates a methodology to discriminate between the performances of different material models within the framework of Material Testing 2.0, which consists in coupling heterogeneous test configurations, full-field measurements using for instance Digital Image Correlation (DIC) and inverse identification like the Virtual Fields Method (VFM). The methodology relies on using a set of different virtual fields for parameter identification with a selected model, and to evaluate the performance of the model. The paper illustrates this methodology on anisotropic metal plasticity.
摘要本文展示了在材料测试 2.0 框架内区分不同材料模型性能的方法,该方法包括将异质测试配置、全场测量(例如使用数字图像相关性(DIC))和反向识别(例如虚拟场方法(VFM))结合起来。该方法依赖于使用一组不同的虚拟场,通过选定的模型进行参数识别,并评估模型的性能。本文以各向异性金属塑性为例说明了这一方法。
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引用次数: 0
Local reinforcement of titanium sheet by means of GTAW droplet deposition for threaded connections 通过 GTAW 熔滴沉积技术局部加固钛板,用于螺纹连接
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-41
H. Vanhove
Abstract. Making threaded connections to thin metal sheets requires locally thickening of the sheet in order to provide enough thread length for a structurally sound connection. Shaped Metal Deposition processes like Gas Tungsten Arc Welding (GTAW) allow to locally build-up material in order to provide thickness for a sufficient length of thread engagement. This publication describes the research towards local thickening of a titanium sheet by means of pulsed Tungsten Inert Gas (TIG) droplet deposition, aimed at creating threaded holes for thin shelled bone fracture fixation plates. The influence of current, weld time and amount of filler material on droplet diameter and height is studied.
摘要在薄金属板上进行螺纹连接时,需要局部加厚金属板,以提供足够的螺纹长度,实现结构合理的连接。气体钨极氩弧焊 (GTAW) 等异型金属沉积工艺可在局部增厚材料,以提供足够长的螺纹啮合厚度。本出版物介绍了通过脉冲钨极惰性气体(TIG)液滴沉积对钛板进行局部增厚的研究,目的是为薄壳骨折固定板制造螺纹孔。研究了电流、焊接时间和填充材料量对液滴直径和高度的影响。
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引用次数: 0
Applying images processing methods for automation measurement of tool-chip contact length in orthogonal cutting 应用图像处理方法自动化测量正交切削中的刀片接触长度
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-229
Camille Favier
Abstract. The simulation of machining process is an essential tool in the digitalization of the entire production chain. Currently, these simulations are not sufficiently precise to avoid the use of experimental tests in order to optimize machining operations and guarantee the quality of the machined parts. Some parameters, such as tool-chip contact length, are still underestimated, although they are critical for controlling heat transfer into the tool and implicitly its wear. In order to validate a numerical cutting simulation model, the tool-chip contact length experimentally measured should be used as a comparative quantity, in the same way as the cutting forces and the morphology of the chips is currently used. The objective of this paper is to propose an automation of tool-chip contact length measurements using image processing algorithms. The proposed algorithm was able to identify and measure the tool-chip contact length on more that 75% of images. The algorithm accuracy is evaluated by comparing computed and manually measured tool-chip contact length, for different cutting conditions. It was found that it overestimates the contact length, especially in the case where the image quality is lower.
摘要加工过程模拟是整个生产链数字化的重要工具。目前,这些模拟还不够精确,无法避免使用实验测试来优化加工操作和保证加工零件的质量。一些参数,如刀具-芯片接触长度,仍然被低估了,尽管它们对于控制刀具的热传导和隐含的磨损至关重要。为了验证数值切削仿真模型,应将实验测量的刀片接触长度作为一个比较量,就像目前使用的切削力和切屑形态一样。本文旨在提出一种利用图像处理算法自动测量刀片接触长度的方法。所提出的算法能够在 75% 以上的图像上识别和测量刀具-切屑接触长度。在不同的切削条件下,通过比较计算得出的刀片接触长度和人工测量的刀片接触长度,对算法的准确性进行了评估。结果发现,该算法高估了接触长度,尤其是在图像质量较低的情况下。
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引用次数: 0
Simulation and monitoring of the infusion of thick composites with thermoplastic acrylic resin 模拟和监测热塑性丙烯酸树脂厚复合材料的灌注过程
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-64
N. Siddig
Abstract. The ZEBRA project aims to advance the circular economy by creating wind turbine blades that can be completely recycled. Currently, Wind turbine blades are fabricated through Vacuum-Assisted Resin Infusion (VARI) using thermoset resins. In this endeavor, the recyclable thermoplastic resin Elium® from Arkema is utilized as a sustainable alternative to traditional thermoset resins. The production of thick and sizable components using reactive resins presents various intertwined physical aspects and difficulties, notably concerning potential overheating during the Elium® radical polymerization process. The optimization of this process necessitates the use of simulation to save the expensive time and effort caused by the experiments. However, to be reliable, these numerical methods must be validated to allow accurate predictions for potential defects with thick and complex parts. The challenge lies in flow front detection in the through-thickness direction. In this work, infusion tests were conducted for thick parts in a testing bench instrumented with a robust monitoring system. QRS sensors are placed through the part thickness to detect the front arrival instantaneously. The simulations are compared and validated to the signals of the QRS sensors for validation. Then the model was used to predict the flow behavior for more complex parts. A 3D flow is observed by the differences in permeability between the flow medium and the fabric, which induces a high difference in resin arrival times to the sensors depending on the position of sensors through the part thickness. The flow simulations showed a good approximation of the experimental results. However, deviations are observed in the flow front position, caused by the disturbance induced by the presence of the sensors.
摘要ZEBRA 项目旨在通过制造可完全回收利用的风力涡轮机叶片来推动循环经济的发展。目前,风力涡轮机叶片是使用热固性树脂通过真空辅助树脂灌注(VARI)制造的。在此过程中,阿科玛公司生产的可回收热塑性树脂 Elium® 被用作传统热固性树脂的可持续替代品。使用反应性树脂生产又厚又大的部件会遇到各种相互交织的物理问题和困难,尤其是在 Elium® 自由基聚合过程中可能出现的过热问题。要优化这一过程,就必须使用仿真技术,以节省实验所需的昂贵时间和精力。但是,这些数值方法必须经过验证,才能准确预测厚而复杂的部件可能存在的缺陷。挑战在于厚度方向的流动前沿检测。在这项工作中,在装有强大监测系统的测试台上对厚部件进行了导流测试。QRS 传感器穿过零件厚度,可瞬时检测前沿的到达。模拟结果与 QRS 传感器的信号进行了比较和验证。然后,模型被用于预测更复杂零件的流动行为。由于流动介质和织物之间的渗透性存在差异,因此可以观察到三维流动,根据传感器在部件厚度上的位置不同,树脂到达传感器的时间也存在很大差异。流动模拟结果与实验结果十分接近。然而,由于传感器的存在造成的干扰,流动前沿位置出现了偏差。
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引用次数: 0
Investigations on the production and forming of thermoplastic ceramic green tapes 热塑性陶瓷绿色胶带的生产和成型研究
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-272
R. Tran
Abstract. Technical ceramics such as alumina with its temperature stability, high mechanical stiffness, and good dielectric strength at low density, meet the requirements for highly resilient components for promising markets of high-performance electronics and the electrification of mobility. Ceramic components are usually manufactured using powder technology processes since forming of sintered ceramics is not possible due to the lack of plasticity. In this work, we use hydroforming to shape thermoplastic ceramic green tapes prior to sintering to add a third dimension to flat substrates. We developed alumina feedstocks based on a polyamide binder system that were extruded to 1 mm thick tapes, hydroformed, debinded and sintered. Depending on the binder composition, forming temperatures of 45-60 °C were sufficient, whereby precise temperature control was crucial for success. As a result, components with forming depths of up to 5 mm were produced without defects. This process offers the potential to revolutionize this market segment, not only in terms of geometric design freedom and low material waste, but also in terms of profitability of mass production.
摘要。氧化铝等技术陶瓷具有温度稳定性、高机械刚度和低密度下良好的介电强度,可满足高性能电子产品和移动设备电气化等前景广阔的市场对高弹性元件的要求。陶瓷元件通常采用粉末技术工艺制造,因为烧结陶瓷缺乏可塑性,无法成型。在这项工作中,我们采用水压成型技术,在烧结前对热塑性陶瓷绿带进行成型,从而为平面基底增加第三个维度。我们开发了基于聚酰胺粘合剂系统的氧化铝原料,将其挤压成 1 毫米厚的带子,然后进行水压成型、脱模和烧结。根据粘合剂成分的不同,成型温度为 45-60 °C即可,因此精确的温度控制是成功的关键。因此,成型深度达 5 毫米的部件在生产过程中不会出现缺陷。这种工艺不仅在几何设计自由度和低材料浪费方面,而且在批量生产的盈利能力方面,都为这一细分市场提供了革命性的潜力。
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引用次数: 0
Automatic planning strategy for robotic lay-up of prepregs on a complex-shaped mold 机器人在复杂形状模具上铺设预浸料的自动规划策略
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-62
A. Gambardella
Abstract. The evolution of composite component production has been driven by a constant quest for improvements in process efficiency, precision, and repeatability. The eventual transition from traditional hand layup to robotic layup represents a significant step in this evolution. The implementation of robotic layup systems has become increasingly prevalent in the manufacturing industry, particularly in the aerospace and automotive sectors, where lightweight, strength, and precision are mandatory requirements. Ideally, the goal is the development of processes where a highly precise robotic arm could automate the deposition of composite materials onto the mold, providing a certain reduction of human errors, and minimizing material waste and associated costs. In this context, this paper proposes a computational tool that is able to provide automatic layup planning for the robotic layup process. The implemented algorithm incorporates the knowledge of a professional laminator: it can automatically analyze a generic mold surface of complex shape, work out the correct strategies for lamination, and generate instructions for robot movements.
摘要复合材料部件生产的发展是由对工艺效率、精度和可重复性的不断追求所推动的。从传统的手工铺层最终过渡到机器人铺层是这一演变过程中的重要一步。机器人铺层系统的应用在制造业中越来越普遍,尤其是在航空航天和汽车行业,因为这些行业对轻量化、强度和精度有着严格的要求。理想情况下,我们的目标是开发一种工艺,使高精度机械臂能够自动将复合材料沉积到模具上,从而在一定程度上减少人为失误,并最大限度地减少材料浪费和相关成本。在此背景下,本文提出了一种能够为机器人铺层工艺提供自动铺层规划的计算工具。所实施的算法结合了专业层压机的知识:它可以自动分析形状复杂的通用模具表面,制定正确的层压策略,并生成机器人运动指令。
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引用次数: 0
Nano-texturing orientation effect on the piercing behavior of five stacked amorphous electrical steel sheets 纳米纹理取向对五种叠层非晶电工钢片穿孔行为的影响
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-274
Tomomi Shiratori
Abstract. Higher efficiency motor becomes an expecting keyword in the sustainable society. The iron core in these motors is fabricated by piercing the amorphous electrical steel sheet with sufficient dimensional accuracy and without defects. However, this material has 2.2 GPa in the tensile strength, no ductility, and over 900 HV in hardness. Furthermore, tool life was limited to be short. In recent years, some new tooling technologies for piercing amorphous electrical steel sheets have been developed to reduce the induced damages into punched sheets.Especially, when using nano-textured tool, the process affected width was more reduced than using the none-textured tools. In the present study, nano-texturing orientation effect on the piercing behavior is investigated and its mechanism is discussed.
摘要在可持续发展的社会中,高效电机已成为一个令人期待的关键词。这些电机中的铁芯是由非晶电工钢板制成的,具有足够的尺寸精度和无缺陷。然而,这种材料的抗拉强度为 2.2 GPa,没有延展性,硬度超过 900 HV。此外,工具寿命也很短。近年来,一些用于非晶电工钢片穿孔的新工具技术得到了发展,以减少对冲孔钢片的诱导损伤,特别是在使用纳米纹理工具时,工艺影响宽度比使用无纹理工具更小。本研究探讨了纳米纹理取向对穿孔行为的影响及其机理。
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引用次数: 0
Numerical modelling of the micro-cutting in the abrasion process with pyramidal indenter 金字塔形压头磨损过程中的微切削数值建模
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-204
Achref Werchfeni
Abstract. A 3-D finite element model of abrasion process based on a CEL (Coupled Eulerian-Lagrangian) approach was developed. A scratch test on elastic-perfectly plastic materials with a pyramidal indenter was simulated. The influence of the interfacial friction coefficient f, the geometric parameters of the indenter and the cutting conditions on the overall friction coefficient μ were studied. Subsequently, the finite element simulation results were compared with an analytical model. It was found that the µ increases linearly with the friction coefficient f and the attack angle of grit β. The FE model results present a good agreement with the analytical model results.
摘要基于 CEL(欧拉-拉格朗日耦合)方法开发了磨损过程的三维有限元模型。模拟了使用金字塔形压头对弹性完全塑性材料进行的划痕试验。研究了界面摩擦系数 f、压头几何参数和切削条件对总体摩擦系数 μ 的影响。随后,将有限元模拟结果与分析模型进行了比较。结果发现,μ 随摩擦系数 f 和磨粒攻击角 β 的增大而线性增大。
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引用次数: 0
On the impact welding of dissimilar alloys for use in multimaterial skeletal fixation devices 多材料骨骼固定装置中使用的异种合金的冲击焊接
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-192
M. Sanguedolce
Abstract. Multi-material skeletal fixators appear to be a promising approach to reduce failure due to the high stiffness of standard-of-care fixators. Nevertheless, joining different materials is challenging due to their different properties. High-velocity impact welding, a solid-state welding process, involves the collision of a “flyer” (moving) part with a stationary “target” at very high speed (i.e., hundreds of meters per second). In this paper we present a preliminary experimental campaign to use laser impact welding to join NiTi and Mg alloy Mg-1.2Zn-0.5Ca-0.5Mn (wt%) sheets and the parallel development of a finite element model to allow gathering further insights into the complex phenomena involved in the process. Preliminary results show the deposition of the Mg alloy on NiTi sheets by tuning the joining process conditions and promising results of the numerical model in terms of accordance with experiments: these findings provide the basis for further process optimization, numerical model calibration and the application of a valid protocol for multi-material skeletal fixation devices.
摘要。多材料骨骼固定器似乎是一种很有前景的方法,可减少因标准固定器的高刚度而导致的失效。然而,由于不同材料的特性各异,将它们连接在一起具有挑战性。高速冲击焊接是一种固态焊接工艺,涉及 "飞行器"(移动)部件与静止 "目标 "的高速碰撞(即每秒数百米)。在本文中,我们介绍了使用激光冲击焊接连接镍钛和镁合金 Mg-1.2Zn-0.5Ca-0.5Mn (重量百分比)板材的初步实验活动,并同时开发了一个有限元模型,以便进一步了解焊接过程中的复杂现象。初步结果显示,通过调整连接工艺条件,镁合金可以沉积在镍钛板上,而且数值模型与实验结果一致,前景看好:这些发现为进一步优化工艺、校准数值模型和应用多材料骨骼固定装置的有效方案奠定了基础。
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引用次数: 0
Influence of toolpath strategies on the final accuracy and thickness distributions in multi-stage incremental forming 刀具路径策略对多级增量成形中最终精度和厚度分布的影响
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-166
M. Vanhulst
Abstract. This study focuses on finding a toolpath strategy for accurately forming geometric details on a preshaped sheet metal part by incremental forming in multiple steps. The final thickness distributions and geometrical accuracy are analyzed for spiraling and dedicated feature toolpath strategies. The results are compared to forming the full part (base shape with details) in a conventional single stage manner. Forming the part in multiple steps did improve the accuracy of the part, by decreasing the underforming of the base shape compared to single stage forming. The observed overforming was highly influenced by the location of the detail. In terms of thickness distributions, the toolpath strategy highly influenced the location of the minimal thickness inside each detail. Here, the dedicated feature toolpath proved to be effective for achieving a more uniform thickness distribution.
摘要本研究的重点是寻找一种刀具路径策略,以便通过多步增量成形在预成形钣金零件上精确成形几何细节。分析了螺旋式和专用特征刀具路径策略的最终厚度分布和几何精度。结果与传统的单步成形整个零件(带细节的基本形状)进行了比较。与单级成形相比,通过减少基本形状的欠成形,多级成形零件确实提高了零件的精度。观察到的过度成形受细节位置的影响很大。就厚度分布而言,刀具路径策略对每个细节内部最小厚度的位置影响很大。在此,专用特征刀具路径被证明能有效实现更均匀的厚度分布。
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引用次数: 0
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Materials Research Proceedings
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