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Application of numerical simulation for lightweight design / Marcel Graf ... [et al.]

Due to the increasing lightweight construction efforts to reduce component weight and thus minimize the energy demand for mobilisation of moving masses, light metals or even plastic applications are growing in importance. In order to realise the process development with consideration of the material...

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Main Authors: Graf, Marcel, Härtel, Sebastian, Awiszus, Birgit
Format: Article
Language:English
Published: Faculty of Mechanical Engineering Universiti Teknologi MARA (UiTM) 2019
Subjects:
Building materials
TJ Mechanical engineering and machinery
Online Access:https://ir.uitm.edu.my/id/eprint/42170/1/42170.pdf
https://ir.uitm.edu.my/id/eprint/42170/
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spelling my.uitm.ir.421702021-09-24T02:57:54Z https://ir.uitm.edu.my/id/eprint/42170/ Application of numerical simulation for lightweight design / Marcel Graf ... [et al.] Graf, Marcel Härtel, Sebastian Awiszus, Birgit Building materials TJ Mechanical engineering and machinery Due to the increasing lightweight construction efforts to reduce component weight and thus minimize the energy demand for mobilisation of moving masses, light metals or even plastic applications are growing in importance. In order to realise the process development with consideration of the material, its behaviour must be known. This paper aims to show the importance of numerical process design and how it can be validated with experiments. For the thermo-mechanical simulation to generate results with high accuracy, the use of real material data is necessary. Depending on the investigated process, different characterisation possibilities are available. Here, the compression test was carried out, for example, to determine the forming behaviour of aluminium (EN AW-6060) and magnesium alloys (AZ31) and for a polyamide without and with glass fibre reinforced (PA 6 and PA6-GF30) on elevated temperatures and strain rates of hot bulk forming processes. In this case, the sample position, especially in the case of the polyamide, received increased attention. Thus, it was found that glass fibre reinforced plastics (PA-GF30) can be compressed differently in the longitudinal direction than perpendicular to the extrusion direction. Furthermore, an enhancement of the forming limit and a reduction of the forming force with increasing temperature could be observed for all investigated materials. In addition to the forming behaviour, the thermo-dynamic material properties are at least just as important for the purposed thermo-mechanical process simulations. These were also determined by experimental simulation for the analysed materials in order to regard the internal microstructure. Then, the implementation of all these material data into the FE software simufact.forming V15 and MSC Marc/Mentat was carried out in order to predict a forging process as well as an additive manufacturing process for the semi-finished products. Finally, the calibration of the FE models took place to verify their accuracy. This is the first study undertaken to characterise the forming behaviour of plastics and to study the production of layered magnesium components for further forming processes. Faculty of Mechanical Engineering Universiti Teknologi MARA (UiTM) 2019 Article PeerReviewed text en https://ir.uitm.edu.my/id/eprint/42170/1/42170.pdf ID42170 Graf, Marcel and Härtel, Sebastian and Awiszus, Birgit (2019) Application of numerical simulation for lightweight design / Marcel Graf ... [et al.]. Journal of Mechanical Engineering (JMechE), SI 8 (1). pp. 176-191. ISSN 18235514
institution Universiti Teknologi Mara
building Tun Abdul Razak Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider Universiti Teknologi Mara
content_source UiTM Institutional Repository
url_provider http://ir.uitm.edu.my/
language English
topic Building materials
TJ Mechanical engineering and machinery
spellingShingle Building materials
TJ Mechanical engineering and machinery
Graf, Marcel
Härtel, Sebastian
Awiszus, Birgit
Application of numerical simulation for lightweight design / Marcel Graf ... [et al.]
description Due to the increasing lightweight construction efforts to reduce component weight and thus minimize the energy demand for mobilisation of moving masses, light metals or even plastic applications are growing in importance. In order to realise the process development with consideration of the material, its behaviour must be known. This paper aims to show the importance of numerical process design and how it can be validated with experiments. For the thermo-mechanical simulation to generate results with high accuracy, the use of real material data is necessary. Depending on the investigated process, different characterisation possibilities are available. Here, the compression test was carried out, for example, to determine the forming behaviour of aluminium (EN AW-6060) and magnesium alloys (AZ31) and for a polyamide without and with glass fibre reinforced (PA 6 and PA6-GF30) on elevated temperatures and strain rates of hot bulk forming processes. In this case, the sample position, especially in the case of the polyamide, received increased attention. Thus, it was found that glass fibre reinforced plastics (PA-GF30) can be compressed differently in the longitudinal direction than perpendicular to the extrusion direction. Furthermore, an enhancement of the forming limit and a reduction of the forming force with increasing temperature could be observed for all investigated materials. In addition to the forming behaviour, the thermo-dynamic material properties are at least just as important for the purposed thermo-mechanical process simulations. These were also determined by experimental simulation for the analysed materials in order to regard the internal microstructure. Then, the implementation of all these material data into the FE software simufact.forming V15 and MSC Marc/Mentat was carried out in order to predict a forging process as well as an additive manufacturing process for the semi-finished products. Finally, the calibration of the FE models took place to verify their accuracy. This is the first study undertaken to characterise the forming behaviour of plastics and to study the production of layered magnesium components for further forming processes.
format Article
author Graf, Marcel
Härtel, Sebastian
Awiszus, Birgit
author_facet Graf, Marcel
Härtel, Sebastian
Awiszus, Birgit
author_sort Graf, Marcel
title Application of numerical simulation for lightweight design / Marcel Graf ... [et al.]
title_short Application of numerical simulation for lightweight design / Marcel Graf ... [et al.]
title_full Application of numerical simulation for lightweight design / Marcel Graf ... [et al.]
title_fullStr Application of numerical simulation for lightweight design / Marcel Graf ... [et al.]
title_full_unstemmed Application of numerical simulation for lightweight design / Marcel Graf ... [et al.]
title_sort application of numerical simulation for lightweight design / marcel graf ... [et al.]
publisher Faculty of Mechanical Engineering Universiti Teknologi MARA (UiTM)
publishDate 2019
url https://ir.uitm.edu.my/id/eprint/42170/1/42170.pdf
https://ir.uitm.edu.my/id/eprint/42170/
_version_ 1712288328980627456
score 13.211869

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