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2013 | Book

Introduction Read chapter Read first chapter

Modeling of Thermo-Electro-Mechanical Manufacturing Processes

Applications in Metal Forming and Resistance Welding

Authors: C. V. Nielsen, W. Zhang, L. M. Alves, N. Bay, P. A. F. Martins

Publisher: Springer London

Book Series : SpringerBriefs in Applied Sciences and Technology

Part of: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik"

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About this book

Modeling of Thermo-Electro-Mechanical Manufacturing Processes with Applications in Metal Forming and Resistance Welding provides readers with a basic understanding of the fundamental ingredients in plasticity, heat transfer and electricity that are necessary to develop and proper utilize computer programs based on the finite element flow formulation.

Computer implementation of a wide range of theoretical and numerical subjects related to mesh generation, contact algorithms, elasticity, anisotropic constitutive equations, solution procedures and parallelization of equation solvers is comprehensively described.

Illustrated and enriched with selected examples obtained from industrial applications, Modeling of Thermo-Electro-Mechanical Manufacturing Processes with Applications in Metal Forming and Resistance Welding works to diminish the gap between the developers of finite element computer programs and the professional engineers with expertise in industrial joining technologies by metal forming and resistance welding.

Table of Contents

Frontmatter
Chapter 1. Introduction
Abstract
Taking a general view of the present state of the art in terms of modeling and computation of manufacturing processes it appears that the finite element flow formulation is one of the most widespread numerical methodologies for the analysis of complex, industrial metal forming and resistance welding processes.
C. V. Nielsen, W. Zhang, L. M. Alves, N. Bay, P. A. F. Martins
Chapter 2. Finite Element Formulations
Abstract
The governing equations for problems solved by the finite element method are typically formulated by partial differential equations in their original form. These are rewritten into a weak form, such that domain integration can be utilized to satisfy the governing equations in an average sense.
C.V. Nielsen, W. Zhang, L.M. Alves, N Bay, P.A.F. Martins
Chapter 3. Coupled Finite Element Flow Formulation
Abstract
This chapter presents a coupled finite element approach for thermo-mechanical modeling of metal forming and for electro-thermo-mechanical modeling of resistance welding. The finite element approach is based on the flow formulation which was described in Chapter 2 as one of the implicit quasi-static formulations.
C.V. Nielsen, W. Zhang, L.M. Alves, N. Bay, P.A.F. Martins
Chapter 4. Contact Modeling
Abstract
Due to the highly non-linear behavior, contact modeling remains among the more difficult disciplines within finite element simulations. Contact between workpieces and tooling and in-between workpieces defines the shape of formed components in metal forming as well as the contact conditions in resistance welding between the components to be joined and the welding electrodes.
C. V. Nielsen, W. Zhang, L. M. Alves, N. Bay, P. A. F. Martins
Chapter 5. Meshing and Remeshing
Abstract
A significant amount of time in finite element modeling of manufacturing processes is spent in mesh generation. Setting up three-dimensional meshes is a cumbersome task due to complexity of the processes and the involved geometries. Moreover, additional meshing challenges often appear due to the fact that manufacturing processes based on large plastic deformations present progressive mesh distortion (or degeneracy), potential interference between mesh and contour of the tools and possible contact of the mesh with itself. This poses the need for robust, automatic, mesh generation and regeneration (remeshing) procedures in order to ensure that complex processes are modeled from the beginning to the end with high levels of accuracy both in terms of geometry and distribution of field variables.
C. V. Nielsen, W. Zhang, L. M. Alves, N. Bay, P. A. F. Martins
Chapter 6. Parallelization of Equation Solvers
Abstract
When solving large finite element problems, solution time becomes a factor which cannot be ignored. It is among the concerns when considering modeling in three dimensions instead of two dimensions. Different approaches are available to reduce the computational cost.
C. V. Nielsen, W. Zhang, L. M. Alves, N. Bay, P. A. F. Martins
Chapter 7. Material, Friction and Contact Characterization
Abstract
Awareness and understanding of the basic procedures to determine the flow stress, the frictional response and the electric and thermal contact resistances under different conditions of strain-rate and temperature are fundamental for improving the quality of data to be inserted in finite element computer programs. Because accuracy and reliability of numerical simulations are critically dependent on input data, the following sections will provide a brief overview of the most widespread experimental techniques that are utilized for material, friction and contact characterization.
C. V. Nielsen, W. Zhang, L. M. Alves, N. Bay, P. A. F. Martins
Chapter 8. Applications
Abstract
Accuracy, reliability and validity of the coupled finite element flow formulation are evaluated by performing numerical simulations of industrial manufacturing processes. Emphasis is put on joining technologies by tube forming and resistance welding due to its importance for assembling individual components together in complete and useful end products and also due to the fact that selected applications deal with state-of-the-art engineering concepts that are not commonly available in the open literature. Several of the presented examples are industrial cases.
C. V. Nielsen, W. Zhang, L. M. Alves, N. Bay, P. A. F. Martins
Backmatter
Metadata
Title
Modeling of Thermo-Electro-Mechanical Manufacturing Processes
Authors
C. V. Nielsen
W. Zhang
L. M. Alves
N. Bay
P. A. F. Martins
Copyright Year
2013
Publisher
Springer London
Electronic ISBN
978-1-4471-4643-8
Print ISBN
978-1-4471-4642-1
DOI
https://doi.org/10.1007/978-1-4471-4643-8

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