The main aim of the present work is to develop a cellular automata finite element –artificial neural network (CAFE-ANN) hybrid model to predict the evolution of grain size and yield strength during friction stir welding. The CAFE model was developed by linking CA cells with elements in ABAQUS, a finite element code. Then a neural network was developed and trained appropriately by using the data obtained from the validated CAFE model that predicts the grain size and yield strength. The ANN results are validated. Finally it has been demonstrated that ANN can be used as a ‘virtual machine’ to examine the effect of rotational speed, welding speed, axial force and shoulder diameter on the variation in grain size and yield strength. The temperature and strain-rate distribution predicted by the thermal and strain-rate models are consistent with the existing results. The CAFE model grain size predictions are also accurate as compared to experiments. The grain size and yield strength predictions from ANN coincide well with the experimental values and CAFE model predictions. It has been demonstrated that CAFE-ANN hybrid model can be used as a ‘virtual machine’ to predict and analyze the effect of above said parameters on the grain size and yield strength evolution. The predicted influence is found to agree with some of the available results. In few cases, a slight deviation in the trend is witnessed as compared to literature results.
Electromagnetic Forming (EMF) is a high-speed forming process that can be applied for shaping, joining and cutting of workpieces made of electrically conductive material eg. aluminium. This paper proposes a dual electromagnetic forming method. Energy efficiency of the dual electromagnetic forming is compared with the single sided electromagnetic forming using FEM simulations. In uniform pressure rectangular coil, the top layer of the coil assists in the deformation of the workpiece while the bottom layer hinders the workpiece deformation.To make the bottom layer of the coil also to assist in the deformation of the workpiece, a uniform pressure rectangular coil is designed and placed between the two sheet metal workpiece. The efficiency of the two processes are compared by determing the maximum deformation obtained for each case.
Abstract:The paper focuses on the study of expansion velocity and effective plastic strain with numerical analysis of electromagnetic tube expansion. Effects of process parameters on EM free expansion of tube are discussed in detail. FEM results are obtained through 3D simulations with the help of EM module in LS-DYNA TM in which finite element method (FEM) for conductor and boundary element method (BEM) for surrounding air is implemented. FEM and BEM results are obtained from simulation and compared with available experimental data in the published literature. Increase in capacitance to increase energy is not favourable for electromagnetic forming. Variation in voltage to increase energy is suitable for electromagnetic forming.
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