The Experts below are selected from a list of 2211 Experts worldwide ranked by ideXlab platform

Gow Yi Tzou - One of the best experts on this subject based on the ideXlab platform.

  • FEM Analysis and Experiment Validation on Multi-Pass Forging of Torx Round Flange Bolt
    International Journal of Automotive Technology, 2020
    Co-Authors: Shih-hsien Lin, Dyi-cheng Chen, Un-chin Chai, Gow Yi Tzou
    Abstract:

    This study aims at exploring the multi-pass Forging of Torx Round Flange Bolt (automotive fastener) to simulate each pass Forging process using FEM simulation. The software is used to carry out the simulation analysis. Constant shear friction is always assumed at the interface between die and workpiece to explore the effective stress, the effective strain, the velocity filed, and the Forging Force for each pass. Through the pass schedule plan and design based on FEM analysis, the four-pass Forging process is designed to form the Torx Round Flange Bolt compared the five-pass Forging. It is noted that the total Forging Force is 1,204 kN, so the 200 tons machinery in the factory can be chosen to manufacture this automotive fastener. The die stress analysis for each pass has been explored to realize whether the dies are damaged or not. The forming feasibility of Torx Round Flange Bolt can be performed by FEM simulation. All dies designs and forming results can be proposed to the dies manufacture so as to perform the realistic experiments. Comparisons between FEM and experiment for final product dimensions can be carried out. The maximum dimension error is just around 3.32% to show a good agreement with the experiment. The research results can provide to the industries as the references of establishment of multi-pass Forging technology.

  • Study on Multi-Stage Cold Forging of Stainless Automotive Battery Fastener
    2015
    Co-Authors: Ming Chao Sun, Gow Yi Tzou, Liang An Zheng
    Abstract:

    Abstract. Stainless automotive battery fastener requires high dimension precision and narrow tolerance. In order to save the developing cost and accumulate more production design experiences, CAD/CAE technology has been used in multi-stage cold Forging with five stages to shorten our developing cycle time. In this paper, the CAD drawing is made by Inventor 3D software, then import the STL file to DEFORM-3D software to do the settings of pre-process and simulation analysis. Effective stress, effective strain, velocity field, and Forging Force have been shown in this study. Finally, the actual manufacture measurement results compares with simulation datum to verify the analysis acceptance. After comparing the FEM simulation results with actual forming measurements, the error rate of washer diameter is increased in fourth stage. Although the measurement results are still in tolerance, the future work is to decrease the error rate through optimizing the mold design of fourth stage. The verification is performed to reduce the error rate according to the research method proposed in the study. On the other hand, the mold life in the actual forming is found to be easily damaged in the fifth stage. In the future, production improvement should be done through modifying the design of mold and die for the third and the fourth stages, the life of mold and die is explored to reduce the Forging Force in the fifth stage

  • The die stress and Forging streamline analysis of stainless automotive battery fastener
    Materials Research Innovations, 2014
    Co-Authors: Gow Yi Tzou, Ming Chao Sun, Liang An Zheng
    Abstract:

    The study aims at the stainless automobile battery fastener Forging to perform a series of forming simulations and experimental verifications. The fastener Forging analysis regarding effective stress, effective strain, velocity field, Forging streamline, die effective stress and Forging Force has been explored by a finite element method simulation and approved by experimental results. Industrial application of mass production has been shown well too. It is noted that the die stress and the Forging streamline analysis are of great importance in the mould and die design. The realistic die situation can prove the position which occurs when the maximum die stress simulated by the finite element method, and the Forging streamline simulation can compare with the experimental results.

  • Processing animation simulation and FEM analysis of multi-stage cold Forging of stainless automotive battery fastener
    Indian Journal of Engineering and Materials Sciences, 2013
    Co-Authors: Ming Chao Sun, Gow Yi Tzou, Liang An Zheng
    Abstract:

    The study proposes processing animation simulation, FEM analysis, and experimental verification of multi-stage Forging of stainless automotive battery fastener. The processing animation simulation can provide the realistic motions for each pass to realize how to work for the front punch and die. Stainless automotive battery fastener requires high dimension precision and narrow tolerance. In order to save the developing cost and accumulate more production design experiences, CAD/CAE technology has been used in multi-stage cold Forging with five stages to shorten our developing cycle time. In this paper, the CAD drawing is made by Inventor 3D software, then import the STL file to DEFORM-3D software to do the settings of pre-process and simulation analysis. Effective stress, effective strain, velocity field, and Forging Force have been shown in this study. Finally, the actual manufacture measurement results compares with simulation datum to verify the analysis acceptance. After comparing the FEM simulation results with actual forming measurements, the error rate of washer diameter is increased in fourth stage. Although the measurement results are still in tolerance, the future work is to decrease the error rate through optimizing the mold design of fourth stage. The verification is performed to reduce the error rate according to the research method proposed in the study. On the other hand, the mold life in the actual forming is found to be easily damaged in the fifth stage. In the future, production improvement should be done through modifying the design of mold and die for the third and the fourth stages, the life of mold and die is explored to reduce the Forging Force in the fifth stage.

  • Die Stress and Forging Stream Line Analysis of Multi-Stage Forging of Hexagonal Flange Vehicle Bolt
    2013
    Co-Authors: Yung-tian Liu, Gow Yi Tzou
    Abstract:

    Finite Element Method can be used to the analysis of fasteners forming and the dies design before realistic forming, the problems and optimal design can be solved and obtained by FEM simulation. The development time and cost of products can be reduced and the competitiveness of products can be raised. In this study, the multi-stage Forging analysis of hexagonal flange vehicle bolt can be simulated by three-dimensional rigid-plastic finite element method. Using the SolidWorks drawing software to conduct the dies and the work-piece, the DEFORM 3D finite element software can be used to simulate and analyze assuming constant shear friction, the effective stress, the effective strain, the velocity field, the Forging Force and the shape dimensions of fastener can be

Liang An Zheng - One of the best experts on this subject based on the ideXlab platform.

  • Study on Multi-Stage Cold Forging of Stainless Automotive Battery Fastener
    2015
    Co-Authors: Ming Chao Sun, Gow Yi Tzou, Liang An Zheng
    Abstract:

    Abstract. Stainless automotive battery fastener requires high dimension precision and narrow tolerance. In order to save the developing cost and accumulate more production design experiences, CAD/CAE technology has been used in multi-stage cold Forging with five stages to shorten our developing cycle time. In this paper, the CAD drawing is made by Inventor 3D software, then import the STL file to DEFORM-3D software to do the settings of pre-process and simulation analysis. Effective stress, effective strain, velocity field, and Forging Force have been shown in this study. Finally, the actual manufacture measurement results compares with simulation datum to verify the analysis acceptance. After comparing the FEM simulation results with actual forming measurements, the error rate of washer diameter is increased in fourth stage. Although the measurement results are still in tolerance, the future work is to decrease the error rate through optimizing the mold design of fourth stage. The verification is performed to reduce the error rate according to the research method proposed in the study. On the other hand, the mold life in the actual forming is found to be easily damaged in the fifth stage. In the future, production improvement should be done through modifying the design of mold and die for the third and the fourth stages, the life of mold and die is explored to reduce the Forging Force in the fifth stage

  • The die stress and Forging streamline analysis of stainless automotive battery fastener
    Materials Research Innovations, 2014
    Co-Authors: Gow Yi Tzou, Ming Chao Sun, Liang An Zheng
    Abstract:

    The study aims at the stainless automobile battery fastener Forging to perform a series of forming simulations and experimental verifications. The fastener Forging analysis regarding effective stress, effective strain, velocity field, Forging streamline, die effective stress and Forging Force has been explored by a finite element method simulation and approved by experimental results. Industrial application of mass production has been shown well too. It is noted that the die stress and the Forging streamline analysis are of great importance in the mould and die design. The realistic die situation can prove the position which occurs when the maximum die stress simulated by the finite element method, and the Forging streamline simulation can compare with the experimental results.

  • Processing animation simulation and FEM analysis of multi-stage cold Forging of stainless automotive battery fastener
    Indian Journal of Engineering and Materials Sciences, 2013
    Co-Authors: Ming Chao Sun, Gow Yi Tzou, Liang An Zheng
    Abstract:

    The study proposes processing animation simulation, FEM analysis, and experimental verification of multi-stage Forging of stainless automotive battery fastener. The processing animation simulation can provide the realistic motions for each pass to realize how to work for the front punch and die. Stainless automotive battery fastener requires high dimension precision and narrow tolerance. In order to save the developing cost and accumulate more production design experiences, CAD/CAE technology has been used in multi-stage cold Forging with five stages to shorten our developing cycle time. In this paper, the CAD drawing is made by Inventor 3D software, then import the STL file to DEFORM-3D software to do the settings of pre-process and simulation analysis. Effective stress, effective strain, velocity field, and Forging Force have been shown in this study. Finally, the actual manufacture measurement results compares with simulation datum to verify the analysis acceptance. After comparing the FEM simulation results with actual forming measurements, the error rate of washer diameter is increased in fourth stage. Although the measurement results are still in tolerance, the future work is to decrease the error rate through optimizing the mold design of fourth stage. The verification is performed to reduce the error rate according to the research method proposed in the study. On the other hand, the mold life in the actual forming is found to be easily damaged in the fifth stage. In the future, production improvement should be done through modifying the design of mold and die for the third and the fourth stages, the life of mold and die is explored to reduce the Forging Force in the fifth stage.

Ming Chao Sun - One of the best experts on this subject based on the ideXlab platform.

  • Study on Multi-Stage Cold Forging of Stainless Automotive Battery Fastener
    2015
    Co-Authors: Ming Chao Sun, Gow Yi Tzou, Liang An Zheng
    Abstract:

    Abstract. Stainless automotive battery fastener requires high dimension precision and narrow tolerance. In order to save the developing cost and accumulate more production design experiences, CAD/CAE technology has been used in multi-stage cold Forging with five stages to shorten our developing cycle time. In this paper, the CAD drawing is made by Inventor 3D software, then import the STL file to DEFORM-3D software to do the settings of pre-process and simulation analysis. Effective stress, effective strain, velocity field, and Forging Force have been shown in this study. Finally, the actual manufacture measurement results compares with simulation datum to verify the analysis acceptance. After comparing the FEM simulation results with actual forming measurements, the error rate of washer diameter is increased in fourth stage. Although the measurement results are still in tolerance, the future work is to decrease the error rate through optimizing the mold design of fourth stage. The verification is performed to reduce the error rate according to the research method proposed in the study. On the other hand, the mold life in the actual forming is found to be easily damaged in the fifth stage. In the future, production improvement should be done through modifying the design of mold and die for the third and the fourth stages, the life of mold and die is explored to reduce the Forging Force in the fifth stage

  • The die stress and Forging streamline analysis of stainless automotive battery fastener
    Materials Research Innovations, 2014
    Co-Authors: Gow Yi Tzou, Ming Chao Sun, Liang An Zheng
    Abstract:

    The study aims at the stainless automobile battery fastener Forging to perform a series of forming simulations and experimental verifications. The fastener Forging analysis regarding effective stress, effective strain, velocity field, Forging streamline, die effective stress and Forging Force has been explored by a finite element method simulation and approved by experimental results. Industrial application of mass production has been shown well too. It is noted that the die stress and the Forging streamline analysis are of great importance in the mould and die design. The realistic die situation can prove the position which occurs when the maximum die stress simulated by the finite element method, and the Forging streamline simulation can compare with the experimental results.

  • Processing animation simulation and FEM analysis of multi-stage cold Forging of stainless automotive battery fastener
    Indian Journal of Engineering and Materials Sciences, 2013
    Co-Authors: Ming Chao Sun, Gow Yi Tzou, Liang An Zheng
    Abstract:

    The study proposes processing animation simulation, FEM analysis, and experimental verification of multi-stage Forging of stainless automotive battery fastener. The processing animation simulation can provide the realistic motions for each pass to realize how to work for the front punch and die. Stainless automotive battery fastener requires high dimension precision and narrow tolerance. In order to save the developing cost and accumulate more production design experiences, CAD/CAE technology has been used in multi-stage cold Forging with five stages to shorten our developing cycle time. In this paper, the CAD drawing is made by Inventor 3D software, then import the STL file to DEFORM-3D software to do the settings of pre-process and simulation analysis. Effective stress, effective strain, velocity field, and Forging Force have been shown in this study. Finally, the actual manufacture measurement results compares with simulation datum to verify the analysis acceptance. After comparing the FEM simulation results with actual forming measurements, the error rate of washer diameter is increased in fourth stage. Although the measurement results are still in tolerance, the future work is to decrease the error rate through optimizing the mold design of fourth stage. The verification is performed to reduce the error rate according to the research method proposed in the study. On the other hand, the mold life in the actual forming is found to be easily damaged in the fifth stage. In the future, production improvement should be done through modifying the design of mold and die for the third and the fourth stages, the life of mold and die is explored to reduce the Forging Force in the fifth stage.

Tung-sheng Yang - One of the best experts on this subject based on the ideXlab platform.

  • Flow Stress and Friction of AL6061 and Application to the Cellphone Shell Forging
    Key Engineering Materials, 2019
    Co-Authors: Tung-sheng Yang, Fu Nong Hsu
    Abstract:

    Predictive power and final shape are very important in the Forging process. This study used a finite element method to analyze the Forging Force, final shape and stress distribution of the cellphone shell Forging at different temperatures. To predict the results of FEM simulation accurately, the stress flow and friction factor play an important role. The AL-6061 stress-strain curve at different temperatures was obtained from the compression test of the universal material testing machine. The friction factor between Al-6061 alloy and die is determined by ring compression test.The stress-strain curve and friction factor are applied to the finite element analysis of cellphone Forging. Finite element analysis is used to determine the maximum Forging load, effective stress distribution and shape of cellphone shell Forging. Then the cellphone shell is forged with the parameters of finite element analysis results. Finally, the Forging Force and product shape are compared between the experimental data and the simulation results. The dimension of the cellphone shell agree with the initial design and the forming Force does not exceed the maximum allowable Forging load of the machine.

  • Application of FEM and Abductive Network to Determine Forging Force and Billet Dimensions of Near Net-Shape Helical Bevel Gear Forging
    Materials Science Forum, 2018
    Co-Authors: Tung-sheng Yang, Yu Liang Chang
    Abstract:

    In this paper, the use of the finite element method in conjunction with abductive network is presented to predict the maximum Forging Force and the volume of billet during near net-shape helical bevel gear Forging. The maximum Forging load and volume of billet are influenced by the process parameters such as modules, number of teeth, and die temperature. A finite element method is used to investigate the Forging of helical bevel gear. In order to verify the prediction of FEM simulation for Forging load, the experimental data are compared with the results of current simulation. A finite element analysis is also utilized to investigate the process parameters on Forging load and volume of billet. Additionally, the abductive network was applied to synthesize the data sets obtained from the numerical simulation. The prediction models are then established for the maximum Forging load and volume of billet of near net-shape helical bevel gear Forging under a suitable range of process parameters. After the predictions of the maximum Forging Force and the volume of billet, the optimum of the power of Forging machine and the dimensions of billet are determined.

  • Application of Abductive Network and FEM to Predict the Maximum Forging Force and the Final Face Width of Spur Gear
    2016
    Co-Authors: Tung-sheng Yang, Yuan-chuan Hsu
    Abstract:

    Abstract. The process of precision gear Forging has been developed recently because of its advantages of giving high production rates and improved strength. For complete filling up, predicting the power requirement and final face width is an important feature of the Forging process. A finite element analysis is utilized to investigate the maximum Forging Force and final face width under different process parameters such as modules, number of teeth, and the ratio of the height to diameter of billet. The abductive network is then applied to synthesize the data sets obtained from the numerical simulation, and a prediction model is established ultimately. Employing the predictive model can provide valuable references in prediction of the Forging Force and final face width under a suitable range of process parameters

  • Study on the Maximum Forging Load and Final Face Width of Powder Spur Gear Forging
    Materials Science Forum, 2011
    Co-Authors: Tung-sheng Yang, C. Y. Liu
    Abstract:

    Powder Forging combines powder metallurgy and Forging technology, thus possess the advantages of both processes that result in both stronger and yet more versatile products with complicated geometry and arbitrary alloy compositions. For complete filling up, predicting the power requirement and final face width is an important feature of the powder Forging process. In this paper, a finite element method is used to investigate the Forging Force, the final face width and the density variation of the spur gear powder Forging process. In order to verify the FEM simulation results, the experimental data are compared with the results of the current simulation for the Forging Force and the final face width of spur gear. The influences of the parameters such as modules, number of teeth, the initial relative density, the ratio of the height to diameter of billet and friction factor on the Forging Force and the final face width of the billets are also examined.

  • Study on the bulging deformation of the porous metal in upsetting
    Journal of Materials Processing Technology, 2006
    Co-Authors: Tung-sheng Yang, Yuan-chuan Hsu
    Abstract:

    Abstract Forging of sintered porous powder is currently popular in many parts of the world as an economic method of producing high strength, high ductility parts from mental powder. The upsetting of porous metal is one of the main processes in powder Forging. It is important to understand the upsetting bulging and the density variation of the billet in the Forging of porous metal. In this paper, the finite element method is used to investigate the bulging deformation, Forging Force and density variation of the porous metal in upsetting. The influences of the parameters such as the initial height, the initial diameter, the initial relative density of the billets and the friction coefficient on the bulging deformation, Forging Force and the variation of relative density in the billets are also examined.

Fan Yang - One of the best experts on this subject based on the ideXlab platform.

  • improving bonding quality of underwater friction stitch welds by selecting appropriate plug material and welding parameters and optimizing joint design
    Materials & Design, 2016
    Co-Authors: Xunda Zhang, Caiyan Deng, Dongpo Wang, Zhijiang Wang, Jinhu Teng, Wei Xu, Fan Yang
    Abstract:

    Abstract Friction stitch welding of S355 steel was conducted under wet conditions to study the bonding quality. The effects of plug material, joint design, and welding variables on the weld defects, microstructural characteristics, hardness levels, and tensile properties were investigated. The underwater stitch welding performed with a S355 steel plug exhibited visible bonding defects at the weld interface, while the weld with LF2 as the plug material yielded a qualified joint without cracks or discontinuities, provided the plug and hole geometries were well-designed. The LF2-plug-stitch weld contained more upper bainite and fewer lath martensite grains, which was consistent with the substantially decreased hardness values in the weld metal. The joint was designed with large initial contact area and gap between the plug and hole, so a higher amount of heat was generated when welding was started. Further, the welding time was extended from 11 to 16 s, resulting in a larger heat affected zone and the flow of the plasticized (or squeezed) material was improved too. Stitch welds realized with a 40 kN Forging Force exhibited better ultimate tensile strength and elongation than those with a 35 kN Forging Force, when the other conditions were kept constant.