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Simulation of manufacturing sequences for verification of product properties
KTH, School of Industrial Engineering and Management (ITM), Production Engineering.
2009 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The manufacturing sequence may to a large extent influence properties like residual stresses and hardness and, as a consequence, the fatigue life and shape accuracy of a component. By simulating the manufacturing sequence and extract important accumulated data, the possibilities of early analysis of a design concept of a component and optimisation of the complete manufacturing sequence may increase. An established methodology has the potential to reduce physical testing, increase the process knowledge and reduce product development time and costs. This thesis suggests principles for simulating manufacturing sequences for forged and sheet metal-formed components.

It is possible to establish virtual manufacturing sequences and connect different commercial simulation softwares into a chain with support from methods for data communication and in process modelling. However, the data communication has pitfalls and also material data, process data and material models for single processes may be insufficient in order to conduct a quantitative analysis of the accumulated properties. Thus, a thorough validation of the sequential simulation results should be performed. Further, engineering simplifications of the sequence are recommended and e.g. a combination of numerical and empirical methods may be preferable in order to predict accumulated results with high accuracy. Future development concerning standards for data communication as well as meshing, mapping and modelling technique is recommended in order to improve the quality of the accumulated results. Finally, methods for integration of sequential simulation in the overall component design process, including conventional Computer Aided Design (CAD) and Finite Element Analysis (FEA), should be developed. The main advantage of sequential simulation may be conceptual studies of process and material parameter variations and their influence on the final product properties.

Paper I describes how to select the most critical process parameters in a manufacturing sequence. Paper II describes how to establish a sequence using a combination of numerical and empirical methods and paper III describes state of the art concerning shot peening simulation.

Place, publisher, year, edition, pages
Stockholm: KTH , 2009. , 35 p.
Series
Trita-IIP, ISSN 1650-1888 ; 2009:02
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:kth:diva-10217OAI: oai:DiVA.org:kth-10217DiVA: diva2:211480
Presentation
2009-03-27, Brinellsalen M311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)
Supervisors
Available from: 2009-04-15 Created: 2009-04-15 Last updated: 2010-11-04Bibliographically approved
List of papers
1. Statistical methods for extracting and evaluating manufacturing parameters of significant importance to component robustness
Open this publication in new window or tab >>Statistical methods for extracting and evaluating manufacturing parameters of significant importance to component robustness
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2005 (English)Conference paper, Published paper (Refereed)
Abstract [en]

 

The paper presents a methodology developed within the EURobust project (G1RD-CT-2002-00833 and IMS-Robust 97009, www.eurobust.net). Durability and robustness of components are combined effects of external loads, geometrical design, selected materials and manufacturing sequence. The influence of the manufacturing sequence has not yet been explored and implemented in the virtual product development process and this paper presents a new and unique method to help the engineer in invoking the effect of the manufacturing sequence on product properties. The methodology extracts and evaluates manufacturing parameters with a major influence on component durability. The method is a combination of engineering judgement, Variation Mode and Effect Analysis (VMEA), design of experiment plans for computer-based experiments, automatisation of Finite Element simulations and visualisation of results. The paper describes how to use the method when estimating the robustness of a forged steering knuckle where the deep rolling process was identified as the most important manufacturing process in the manufacturing sequence, using Failure Mode and Effect Analysis (FMEA). The impact on residual stresses, surface quality and deformation hardening from the deep rolling parameters such as tool diameter, hydrostatic pressure, circumferential spindle velocity, feed rate, etc was analysed using VMEA. A simulation model of the deep rolling process was developed and the variations of residual stresses as a function of the manufacturing parameters were simulated and analysed using graphical response surfaces. The method will help engineers to better control the design of components taking all aspects, including the manufacturing sequence, into consideration at the early design phase. The method will also increase the knowledge of how the manufacturing processes affect component durability. 

 

National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-25901 (URN)
Conference
8th QMOD conference Palermo, Italy 2005
Note
QC 20101104Available from: 2010-11-04 Created: 2010-11-04 Last updated: 2015-10-16Bibliographically approved
2. Prediciting residual stresses and hardness of a critical component using a combination of numerical and empirical methods
Open this publication in new window or tab >>Prediciting residual stresses and hardness of a critical component using a combination of numerical and empirical methods
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2008 (English)In: Steel Research International Journal, ISSN 1611-3683, no Sp. Iss. 2, 812-819 p.Article in journal (Refereed) Published
Abstract [en]

This paper describes the experiences gained when using numerical and empirical methods in order to predict the accumulated surface characteristics for a safety component after several forging steps, controlled cooling and blasting. The forging steps were simulated in a sequence using one Finite Element (FE) code. The output forging mesh was used as input to the cooling simulation but was too coarse in order to reflect surface characteristics. The decarburisation effect during cooling that may influence the surface characteristics was not included in the cooling model. An attempt to create a parametric model of the blasting machine with output residual stresses and hardness as a function of input residual stresses, hardness and process parameters indicated the need of further investigation concerning the physical phenomena during blasting in the machine. A new method was developed for analysing the influence of the blasted surface texture on the stress intensity. The measured residual stresses and hardness span caused by variations in the blasting process were successfully used together with the stress intensity factor as input to a fatigue strength analysis. In order to establish a seamless chain of models through the manufacturing sequence further development concerning cooling and blasting models is required.

Keyword
Sequential simulation, manufacturing chain, fatigue properties
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-25904 (URN)000267944700116 ()
Note
QC 20101104. 12th International Conference on Metal Forming Cracow, POLAND, SEP 21-24, 2008 Available from: 2010-11-04 Created: 2010-11-04 Last updated: 2015-10-16Bibliographically approved
3. Methods and models for shot peening simulation
Open this publication in new window or tab >>Methods and models for shot peening simulation
2008 (English)In:   proceedings of the Swedish Production Symposium 2008, 2008Conference paper, Published paper (Refereed)
Abstract [en]

 

Virtual methods for prediction of product properties induced by the manufacturing system may be a good support for product development and process optimisation. The shot peening process may increase component fatigue life by the introduction of compressive residual stresses and the goal of this literature survey was to investigate the industrial maturity of numerical models for shot peening simulation, developed in various R&D projects. The knowledge is based on the information in articles mainly presented at conferences arranged by the International Scientific Committee on Shot Peening. Some important aspects when virtually predicting residual stresses after shot peening are summarised. Several solutions were proposed with different geometric target conditions, material models and numbers of shots. A dynamic analysis with bilinear or multilinear hardening conditions where the target is a 3D block or cylinder of a small substrate below the surface may be a good approach. Also a pattern of several shots against the target should be considered. The state of the art concerning numerical models is still on a basic level and alternative methods, like parametric modelling, may therefore be a complement to numerical simulation. Here the user extracts polynomial relations between process parameters and residual stresses based on measurements.

Keyword
Shot peening, FEM, literature survey, process parameters, residual stress
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-25908 (URN)
Conference
Swedish Production Symposium, Stockholm, Sweden, November 2008
Note
QC 20101104Available from: 2010-11-04 Created: 2010-11-04 Last updated: 2015-10-16Bibliographically approved

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