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Go to Editorial ManagerType of metal flow and stress distribution in metal extrusion process is a highly complex for the complicated die design. In this work a finite element simulation of Al-1100 rod extrusion was successfully achieved using the commercial finite element code Deform-3D.The results show that the finite element model was successfully simulate the stress distribution in the direct rod extrusion of Al-1100.Besides that the optimum die angle reduces the magnitude of normal, shear, and effective stresses. We can conclude from this studythat maximum stresses occour when the rod is with contact with the die at exit stage.
This paper deals with the computer simulation of stress distribution in a plane model of mild steel under biaxial tensile loading. The goal is to visualize the crack behavior under deferent ratios of biaxial loading through linear elastic fracture mechanics theory. A finite element method is considered in calculating the mixed mode of stress intensity factor that governing the influence of stresses distribution around the crack. Aspects of crack propagation are considered. It is found that the mw.imum ci..-cumfcrcnce .stress is not of the plane of crack but that inclined by an angle (68) from it.
Due to the extremely complicated thermal cycle for the welding process, the fusion zone and heat-affected zone (HAZ) produce irreversible elastic-plastic deformation and residual stresses. The differential heating of the pipes caused by the weld heat source causes residual stress as a result of the welding process. However, the strength and lifetime of the component are also decreased as a result of residual stresses in and around the weld zone. The objective of this research is to analyze the residual stresses created during the welding process and select the best welding parameters that give the lowest residual stresses in 316SS pipes with 50 mm diameter and 4 mm thickness that were manually welded by used (316) welding wire and using shielded metal arc welding (SMAW) in a single-pass butt joint with the various values for each of current (58 , 68 , 78 , 88) amperes and voltage (22 , 23 , 24 , 25 , 26) volts. The shielded metal arc welding process involves heating, melting, and solidifying the parent metals and filler material in a localized fusion zone by a transient heat source to create a junction between the parent metals. The welding process free from preheating and heat treatment will be obtained. ANSYS Finite Element methods are used to calculate the welding residual stress distribution. The mechanical and thermal models were used to carry out the theoretical analysis. In general, the numerical study found that the residual stress distribution at the weld zone’s center is continuous, rising, and has a value of about (1738 MPa). Additionally, the residual stress at the boundary between the heat-affected zone and the weld zone climbs to a maximum value of around (3799 . 6 MPa). On the other hand, the magnitude of the residual stress in the heat-affected zone of the weld reduces significantly and achieves a minimum value at a position of (20 mm) with a value near zero.
The welding process involves a very complex thermal cycle, resulting in irreversible elastic-plastic deformation, and residual stresses in and around fusion zone and heat-affected zone (HAZ). A residual stress due to welding arises from the differential heating of the pipes due to the weld heat source. However, the presence of residual stresses in and around the weld zone reduces the strength and life of the component. The objective of this work is to measure the welding residual stress in ASTM (A-106 Gr. b) steel pipes with 4" diameter and 6 mm thickness welded manually (SMAW) in a three-pass butt joint. The shielded metal arc welding process consists of heating, melting, and solidification of parent metals and a filler material in a localized fusion zone by a transient heat source to form a joint between the parent metals. The welding process was carried out without preheating and heat treatment. This measurement of residual stress occurs by using the hole-drilling strain gauge method according to (ASTM E-873), and the experimental results for residual stresses obtained from welded carbon steel pipes are used to provide validation for finite element simulations. The welding process and welding residual stress distribution is calculated by Ansys Finite Element techniques. Theoretical considerations can be assessed by a mechanical model. Overall, there is good agreement between the predicted and measured distributions of residual stress, but the magnitude of predicted stress tends to be greater in the welding region.
This study investigates the deep drawing process of carbon fiber-reinforced high-density polyethylene (CF-HDPE) composites through experimental and numerical approaches. The experimental part involved fabricating CF-HDPE sheets and conducting deep drawing operations under controlled parameters (punch speed, temperature, and forming depth) to evaluate material behavior and mechanical properties. Numerically, finite element analysis (FEA) using ABAQUS simulated the forming process, analyzing stress distribution, strain development, and material deformation under varying conditions. Results revealed that increasing forming depth and decreasing forming temperature elevated the required forming force. Comparisons between experimental and numerical outcomes showed consistent trends, though some differences arose due to factors like friction and material nonlinearity. The findings contribute to optimizing deep drawing processes for composite materials, enhancing manufacturing precision, and minimizing material defects.
In this paper friction stir welding process has been studied whereby utilized FEM method (Ansys software ver. 20). The main effective parameter in this process were rotational speed, linear speed, tool shoulder radius, heat transfer coefficient and clamping percentage to study their influence on represent temperature, von misses stress and frictional stress distribution. Because of the difficulty to obtained the number of the simulation cases in order to get the most important results, Taguchi L27 orthogonal array was apply to reduce the total number of the simulation cases. Pure copper (t = 3.18 mm) material type was applied as work plate material. ANOVA statistical tool was utilized to achieved the optimization process after the simulation cases done. Percentage of contribution of each parameter can be obtained by ANOVA table and mean of S/N ratio plot. Validation process was achieved between the Current study and experiment work in the temperature distribution field with percentage of error 2.7 %. From optimization result It is found that the optimum condition in order to obtained good results for temperature was rotational speed of (450 rpm), linear speed (2.75 mm/s), tool shoulder radius (7 mm), heat transfer coefficient (300 w/m 2 K), clamping distance percentage (40 %). And for von misses stress was rotational speed of (550 rpm), linear speed (3 mm/s), tool shoulder radius (7 mm), heat transfer coefficient (300 w/m 2 K), clamping distance percentage (20 %). While for frictional stress was rotational speed of (450 rpm), linear speed (2.5 mm/s), tool shoulder radius (7 mm), heat transfer coefficient (300 w/m 2 K), clamping distance percentage (30 %).