Prediction of stress-strain behaviors in steels using an integrated constitutive, FEM and ANN model

Austenitic steels with a carbon content of 0.0037 to 0.79 wt% C are torsion tested and modeled using a physically based constitutive model and an Integrated Phenomenological and Artificial neural Network (IPANN) model. The prediction of both the constitutive and IPANN models on steel 0.017 wt% C is then evaluated using a finite element (FEM) code ABAQUS with different reduction in the thickness after rolling through one roll stand. It is found that during the rolling process, the prediction accuracy of the reaction force from FEM simulation for both constitutive and IPANN models depends on the strain achieved (average reduction in thickness). By integrating FEM into IPANN model and introducing the product of strain and stress as an input of the ANN model, the accuracy of this integrated FEM and IPANN model is higher than either the constitutive or IPANN model.

Contact pressure and wear in sheet metal forming - an FEM analysis

Wear is the principal cause of tool failure in most sheet metal forming processes. It is well known that the contact pressure between the blank and the tool has a large influence on the wear of the tool, and hence the tool life. This investigation utilises the finite element method to analyse the contact pressure distribution over the die radius for a particular deep drawing process. Furthermore, the evolution of the predicted contact pressure distribution throughout the entire stroke of the punch is also examined. It was found that the majority of the process shows a steady state pressure distribution, with two characteristic peaks over the die radius, at the beginning and end of the sheet contact area. Interestingly, the initial transient contact pressure response showed extremely high localised peak pressures; more than twice that of the steady state peaks. Results are compared to wear reported in the literature, during similar experimental deep drawing processes. Finally, the significance and effect of the results on wear and wear-testing techniques are discussed.

Evaluation of effective material properties of composite materials using special FEM

In the present paper, a novel method using the special 2D finite element method (FEM) and the concept of equivalent homogeneous materials has been employed to evaluate the effective material properties of composites. Special 2D finite elements containing an internal defect or reinforcement have been well developed in order to greatly simplify the numerical modeling of composites. It can assure the high precision especially in the vicinity of defects or reinforcements in composite materials. Some numerical examples will be provided to demonstrate the validity and versatility of the proposed method by comparing the existing results from other literatures.

Damage identification of civil infrastructure in the time domain using FEM calibrated ARMAX model

Due to environmental loads, mechanical damages, structural aging and human factors, civil infrastructure inevitably deteriorate during their service lives. Since their damage may claim human lives and cause significant economic losses, how to identify damages and assess structural conditions timely and accurately has drawn increasingly more attentions from structural engineering community worldwide. In this study, a fast and sensitive time domain damage identification method will be developed. First, a high quality finite element model is built and the structural responses are simulated under different damage scenarios. Based on the simulated data, an Auto Regressive Moving Average Exogenous (ARMAX) model is then developed and calibrated. The calibrated ARMAX model can be used to identify damage in different scenarios through model updating process using clonal selection algorithm (CSA). The identification results demonstrate the performance of the proposed methodology, which has the potential to be used for damage identification in practices.

FEM calibrated ARMAX model updating method for time domain damage identification

Due to environmental loads, mechanical damages, structural aging and human factors, civil infrastructure inevitably deteriorate during their service lives. Since their damage may claim human lives and cause significant economic losses, how to identify damages and assess structural conditions timely and accurately has drawn increasingly more attentions from structural engineering community worldwide. In this study, a fast and sensitive time domain damage identification method will be developed. To do this, a finite element model of a steel pipe laid on the soil is built and the structural responses are simulated under different damage scenarios. Based on the simulated data, an Auto Regressive Moving Average Exogenous (ARMAX) model is then built and calibrated. The calibrated ARMAX model is used to identify different damage scenarios through model updating process using clonal selection algorithm (CSA). The results demonstrate the application potential of the proposed method in identifying the pipeline conditions. To further verify its performance, laboratory tests of a steel pipe laid on the soil with and without soil support (free span damage) are carried out. The identification results of pipe-soil system show that the proposed method is capable of identifying damagein a complex structural system. Therefore, it can be applied to identifying pipeline conditions.

Mechanical behavior of irregular fibers part I : modeling the tensile behavior of linear elastic fibers

Fiber irregularities are inherent to textile fibers, natural fibers in particular. This series of papers examines the impact of fiber irregularity on the mechanical behavior of textile fibers. In the first part, the effect of fiber dimensional irregularities on the tensile behavior of linear elastic fibers is examined, using the finite element method (FEM). Fiber dimensional irregularities are simulated with sine waves of different magnitude and frequency. The results indicate that increasing the level or magnitude of irregularity will decrease the breaking load, breaking elongation and method Young’s modulus of the fiber, while increasing the frequency of irregularity will decrease the breaking load and method Young’s modulus, but the breaking elongation will increase. Fiber dimensional irregularity and the gauge length effect are also simulated in this study.

Mechanical behavior of irregular fibers part III : the flexural buckling behavior

Fiber buckling behavior is associated with fabric-evoked prickle, which affects clothing comfort and aesthetics. In this paper, the flexural buckling behavior of irregular or nonuniform fibers is studied using the finite element method (FEM). Fiber dimensional irregularities are simulated with sine waves of different magnitude, frequency, and initial phase. The critical buckling loads of the simulated fibers are then calculated from the FE model. The results indicate that increasing the level of irregularity will decrease the critical buckling load of fibers, but the effect of the frequency and initial phase of irregularity on fiber buckling behavior is complicated and is affected by fiber diameter and effective length.

Simulation of the fastener manufacturing process

Cold forging of steel has been modelled using a physical simulation and the finite element method (FEM) to predict the conditions under which failure occurs. FEM was performed using FORGE2 software, which allows analysis of two-dimensional, axi-symmetric forging processes. Various cold forming processes were modelled. The material model has been validated through wire drawing and bulging experiments. The results will be applied to cold forging of industrial products such as fasteners.

Effect of membrane stress on surface roughness changes in sheet forming

Friction plays an important role in sheet metal forming (SMF) and the roughness of the surface of the sheet is a major factor that influences friction. In finite element method (FEM) models of metal forming, the roughness has usually been assumed to be constant; even though it is commonly observed that sheet drawn under tension over a tool radius results in the surface becoming shiny, indicating a major change in surface morphology. An elastic–plastic FEM model for micro-contact between a flat surface and a single roughness peak has been developed. The model was used to investigate the effect of the membrane stress in the sheet on the deformation of an artificial roughness peak. From the simulation results, the change in asperity, or deformation of the local peak, for a given nominal tool contact stress is significantly influenced by the local substrate stress. The height of the asperity decreases with increasing substrate stress and the local pressure is much higher than the nominal pressure. In addition, the local contact stress decreases with an increase in the substrate stress levels.

A finite element simulation of micro-mechanical frictional behaviour in metal forming

Friction is a critical factor for sheet metal forming (SMF). The Coulomb friction model is usually used in most finite element (FE) simulation for SMF. However, friction is a function of the local contact deformation conditions, such as local pressure, roughness and relative velocity. Frictional behaviour between contact surfaces can be based on three cases: boundary, hydrodynamic and mixed lubrication. In our microscopic friction model based on the finite element method (FEM), the case of dry contact between sheet and tool has been considered. In the view of microscopic geometry, roughness depends upon amplitude and wavelength of surface asperities of sheet and tool. The mean pressure applied on the surface differs from the pressure over the actual contact area. The effect of roughness (microscopic geometric condition) and relative speed of contact surfaces on friction coefficient was examined in the FE model for the microscopic friction behaviour. The analysis was performed using an explicit FE formulation. In this study, it was found that the roughness of deformable sheet decreases during sliding and the coefficient of friction increases with increasing roughness of contact surfaces. Also, the coefficient of friction increases with the increase of relative velocity and adhesive friction coefficient between contact surfaces.

The combined tensile and torsional behavior of irregular fibers

Most fibers are irregular, and they are often subjected to combined loading conditions during processing and end-use. In this paper, polyester and wool fibers under the combined tensile and torsional loads have been studied for the first time, using the finite element method (FEM). The dimensional irregularities of these fibers are simulated with sine waves of different magnitude and frequency. The breaking load and breaking extension of the fibers at different twist or torsion levels are then calculated from the finite element model. The results indicate that twist and level of fiber irregularity have a major impact on the mechanical properties of the fiber and the effect of the frequency of irregularity is relatively small.

Modeling the tensile behavior of fibers with geometrical and structural irregularities

Virtually all fibers exhibit some dimensional and structural irregularities. These include the conventional textile fibers, the high-performance brittle fibers and even the newly developed nano-fibers. In recent years, we have systematically examined the effect of fiber dimensional irregularities on the mechanical behavior of the irregular fibers. This paper extends our research to include the combined effect of dimensional and structural irregularities, using the finite element method (FEM). The dimensional irregularities are represented by sine waves with a 30 % magnitude of diameter variation while the structural irregularities are represented by longitudinal and horizontal cavities distributed within the fiber structure. The results indicate that fiber geometrical or dimensional variations have a marked influence on the tensile properties of the fiber. It affects not only the values of the breaking load and extension, but also the shape of the load-extension curves. The fiber structural irregularities simulated in this study appear to have little effect on the shape of the load-extension curves.

Numerical modeling of the dynamic tensile behavior of irregular fibers

Most fibers are irregular, and they are often subjected to rapid straining during mechanical processing and end-use applications. In this paper, the effect of fiber dimensional irregularities on the dynamic tensile behavior of irregular fibers is examined, using the finite element method (FEM). Fiber dimensional irregularities are simulated with sine waves of different magnitude (10%, 30% and 50% level of diameter variation). The tensile behavior of irregular fibers is examined at different strain rates (333%/sec, 3,333%/sec and 30,000%/sec). The breaking load and breaking extension of irregular fibers at different strain rates are then calculated from the finite element model. The results indicate that strain rate has a significant effect on the dynamic tensile behavior of an irregular fiber, and that the position of the thinnest segment along the fiber affects the simulation results markedly. Under dynamic conditions, an irregular fiber does not necessarily break at the thinnest segment, which is different from the quasi-static results.