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Artur Prusinowski and Roman Kaczyński

Abstract

The purpose of this research is unsatisfactory state of knowledge of the abrasive wear of composites with thermoplastic polymer as matrix material and reinforcing material in the form of short and focused carbon fibers that can be used in additive manufacturing technologies. The paper presents a conceptual design of an extrusion head used in Fused Deposition Technology, which allows for the implementation of appropriately stacked fibers at the level of detail production. Finite element simulation was performed to simulate the thermal effect of the system to demonstrate the effect of head cooling on the system. The assumed extrusion temperature of the material was obtained at a uniform nozzle temperature and stable temperature of the entire system. Flow simulation of thermoplastic polymer was carried out in the designed extrusion nozzle. By supplying 0.5 mm wire of 1.75 mm diameter thermoplastic material to the nozzle, the extrusion rate was 0.192 m/s. The proper design of the extrusion head for the intended applications has been demonstrated and the purpose of further research in this field has been confirmed.

Open access

Zbigniew Kołakowski and Andrzej Teter

Abstract

A review of papers that investigate the static and dynamic coupled buckling and post-buckling behaviour of thin-walled structures is carried out. The problem of static coupled buckling is sufficiently well-recognized. The analysis of dynamic interactive buckling is limited in practice to columns, single plates and shells. The applications of finite element method (FEM) or/and analytical-numerical method (ANM) to solve interaction buckling problems are on-going. In Poland, the team of scientists from the Department of Strength of Materials, Lodz University of Technology and co-workers developed the analytical-numerical method. This method allows to determine static buckling stresses, natural frequencies, coefficients of the equation describing the post-buckling equilibrium path and dynamic response of the plate structure subjected to compression load and/or bending moment. Using the dynamic buckling criteria, it is possible to determine the dynamic critical load. They presented a lot of interesting results for problems of the static and dynamic coupled buckling of thin-walled plate structures with complex shapes of cross-sections, including an interaction of component plates. The most important advantage of presented analytical-numerical method is that it enables to describe all buckling modes and the post-buckling behaviours of thin-walled columns made of different materials. Thin isotropic, orthotropic or laminate structures were considered.

Open access

Sanghoon Kim, Hyup Jae Chung and Kyongyop Rhee

Abstract

An image processing technique was used to model the internal structure of aluminum foam in finite element analysis in order to predict the compressive behavior of the material. Finite element analysis and experimental tests were performed on aluminum foam with densities of 0.2, 0.25, and 0.3 g/cm3. It was found that although the compressive strength predicted from the finite element analysis was higher than that determined experimentally, the predicted compressive stress-strain curves exhibited a tendency similar to those determined from experiments for both densities. However, the behavior of the predicted compressive stress-strain curves was different from the experimental one as the applied strain increased. The difference between predicted and experimental stress-strain curves in a high strain range was due to contact between broken aluminum foam walls by the large deformation.

Open access

J. Piekło and M. Maj

Abstract

The article presents various aspects of the analysis of the state of stress in carbon block induced by the effect of temperature when a steel pin is connected to the block by pouring a shaped groove with cast iron. Changes in the temperature and state of stress in the block were examined by FEM (Abaqus program). The numerical model was validated by experimental measurements of pin deflection during pouring of the groove with cast iron.

Open access

T. Giętka, K. Ciechacki and T. Kik

Abstract

Analyses based on FEM calculations have significantly changed the possibilities of determining welding strains and stresses at early stages of product design and welding technology development. Such an approach to design enables obtaining significant savings in production preparation and post-weld deformation corrections and is also important for utility properties of welded joints obtained. As a result, it is possible to make changes to a simulated process before introducing them into real production as well as to test various variants of a given solution. Numerical simulations require the combination of problems of thermal, mechanical and metallurgical analysis. The study presented involved the SYSWELD software-based analysis of GMA welded multipass butt joints made of duplex steel sheets. The analysis of the distribution of stresses and displacements were carried out for typical welding procedure as during real welding tests.

Open access

A. Świątoniowski, D. Woźniak and J. Szostak

Abstract

The essential aspect of the MEFASS rolling process is introducing the cyclic axial counter movement of the rolls transverse to the direction of rolling in the course of a band pass through a rolling gap. The effect of a change in the way of deformation obtained in this manner makes it possible to set in one roll pass a deformation several times larger than it is possible in a conventional process. In this paper, upon the basis of the computer model of the MES process, supported by experimental research, the analysis of the influence exerted by the shape of the surface of roll barrels upon the distribution of the intensity of stresses σi and deformations εi in the section of the band being rolled, and also upon the kinematic and force parameters of the process.

Open access

P. Lacki, J. Adamus, W. Wieckowski and J. Winowiecka

In the paper experimental and numerical results of sheet-metal forming of titanium welded blanks are presented. Commercially pure titanium Grade 2 (Gr 2) and Ti6Al4V titanium alloy (Gr 5) are tested. Forming the spherical cups from the welded Gr 2 || Gr 5 blanks, and uniform Gr 2 and Gr 5 blanks is analysed. Numerical simulations were performed using the PamStamp 2G v2012 program based on the finite element method (FEM). Additionally, drawability tests using the tool consisting of die, hemispherical punch and blank-holder were carried out. Thickness changes and plastic strain distributions in the deformed material are analysed. The obtained results show some difficulties occurring during forming of the welded blanks made of titanium sheets at the same thicknesses but at different grades. It provide important information about the process course and might be useful in design and optimization of the sheet-titanium forming process.

Open access

J. Tomczak, Z. Pater and T. Bulzak

Abstract

This paper presents chosen results of theoretical-experimental works concerning forming of hollow shafts forgings from titanium alloys, which are applied in aviation industry. At the first stage of conducted analysis, the forging forming process was modeled by means of finite element method. Calculations were made using software Simufact Forming. On the basis of performed simulations optimal parameters of rotary compression process were determined. Next, experimental tests of forging forming in laboratory conditions were made. For the research needs, a forging aggregate, designed by the Authors, was used. Conducted research works confirmed the possibility of metal forming (by means of rotary compression) of hollow shafts from hard workable titanium alloys. Numerous advantages of rotary compression process, make it attractive both for low series production (aircraft industry) and for mass production (automotive industry).

Open access

J. Tomczak, T. Bulzak and Z. Pater

Abstract

The paper presents a new method for manufacturing hollow shafts, where tubes are used as billet. First, the design of a specially designed forging machine for rotary compression is described. The machine is then numerically tested with regard to its strength, and the effect of elastic strains of the roll system on the quality of produced parts is determined. The machine’s strength is calculated by the finite element method using the NX Nastran program. Technological capabilities of the machine are determined, too. Next, the results of the modeling of the rotary compression process for a hollow stepped shafts by the finite element method are given. The process for manufacturing hollow shafts was modeled using the Simufact.Forming simulation program. The FEM results are then verified experimentally in the designed forging machine for rotary compression. The experimental results confirm that axisymmetric hollow shafts can be produced by the rotary compression method. It is also confirmed that numerical methods are suitable for investigating both machine design and metal forming processes.

Open access

Qinfen Lu, Yunyue Ye and Jianxin Shen

Abstract

The car access time is a key parameter, especially in a huge stereo-garage, where this one should be decreased as much as possible. This paper proposes a novel stereo-garage. Adopting the linear induction motors (LIMs), the system has a simple structure and rapid response capability. In the stereo-garage, several LIMs are installed below the crossbeam on a lifting platform, and several LIMs are fixed on the top of a moving frame. During the operation of LIMs, the moving frame moves forward and backward to reach the required parking place, whereas the crossbeam moves horizontally in order to take or store the vehicle rapidly. All these LIMs are the same and should be designed at a low frequency. The influences of key structure parameters and dynamic performances are investigated, based on FEM. The predicted results are validated by a prototype. Finally, the designed LIMs are successfully applied in two 8-layer stereo-garages.