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Related Concept Videos

Thin-Walled Hollow Shafts01:15

Thin-Walled Hollow Shafts

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In analyzing a thin-walled hollow shaft subjected to torsional loading, a segment with width dx is isolated for examination. Despite its equilibrium state, this segment faces torsional shearing forces at its ends. These forces are quantitatively described by the product of the longitudinal shearing stress on the segment's minor surface and the area of this surface, leading to the concept of shear flow. This shear flow is consistent throughout the structure, indicating a uniform distribution...
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In mechanical engineering, the interaction between a threaded screw shaft and a plate gear involves analyzing the resisting torque on the plate gear that can be overpowered when a specific torsional moment is applied to the shaft. To better comprehend this concept, consider a generic situation with a threaded screw shaft with a given mean radius and lead and a plate gear with a specified mean radius. The coefficient of static friction between the screw and gear is also provided.
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Consider the elastic torsion formula, which applies to a circular shaft with a consistent cross-section. This formula assumes that the shaft's ends are loaded with rigid plates firmly attached. However, in many cases, torques are applied to the shaft through mechanisms like flange couplings or gears, which are connected by keys inserted into keyways. This application method modifies the stress distribution near the point of torque application, causing it to deviate from the distributions...
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In materials that exhibit elastic and plastic behavior, known as elastoplastic materials, residual stresses can accumulate when these materials experience plastic deformation. This deformation arises from either high levels of shearing stress or significant strains. Residual stresses are internal stresses that persist within a material after removing the external force causing deformation. This phenomenon is demonstrated when observing the behavior of a shaft under torque; notably, the...
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Thermo-Mechanical Numerical Simulation of Friction Stir Rotation-Assisted Single Point Incremental Forming of

Marcin Szpunar1, Tomasz Trzepieciński2, Robert Ostrowski3

  • 1Doctoral School of the Rzeszów University of Technology, 12 Powstancow Warszawy Ave., 35-959 Rzeszow, Poland.

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|July 13, 2024
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Summary

Friction stir rotation-assisted single point incremental forming (SPIF) of titanium sheets was modeled using a finite element approach. The validated model accurately predicts forming forces and temperatures, crucial for optimizing this flexible metal forming process.

Keywords:
incremental sheet formingsheet metal formingsingle point incremental formingtitanium sheet

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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Processes
  • Computational Mechanics

Background:

  • Single Point Incremental Forming (SPIF) offers high flexibility and large deformation capabilities in metal forming.
  • Titanium alloys are increasingly used in industries requiring high performance and formability.
  • Accurate modeling of thermo-mechanical processes is essential for optimizing SPIF parameters.

Purpose of the Study:

  • To develop and validate a reliable finite element (FE) based thermo-mechanical model for friction stir rotation-assisted SPIF of titanium sheets.
  • To analyze the formability of 0.4 mm thick commercially pure titanium sheets during the warm forming of conical cones.
  • To investigate the influence of mesh size on the accuracy of forming force predictions.

Main Methods:

  • Numerical modeling using Abaqus/Explicit (version 2019) to simulate the thermo-mechanical behavior during SPIF.
  • Incorporation of complex thermal interactions, including frictional heat generation, into the FE model.
  • Experimental validation using a FLIR T400 infrared camera for temperature measurement and an ARGUS system for thickness analysis.

Main Results:

  • A 1 mm mesh size demonstrated the best agreement with experimental total forming force, with a prediction error of 3%.
  • The FE model predicted the maximum contact zone temperature (157 °C) with a 1.3% error.
  • The model accurately predicted uniform wall thickness in the drawpiece, with minor overestimations of minimum (3.7%) and maximum (5.9%) wall thicknesses.

Conclusions:

  • The developed thermo-mechanical FE model provides a reliable tool for simulating friction stir rotation-assisted SPIF of titanium sheets.
  • The model accurately captures the forming forces, temperature distribution, and thickness variations, crucial for process optimization.
  • This research contributes to the advancement of flexible and efficient manufacturing processes for titanium components.