A numerical simulation of temperature field in plasma-arc forming of sheet metal

Xu, Wen Ji; Fang, Jian; Wang, X.Y.; Wang, T.; Liu, F.; Zhao, Zhiyao

doi:10.1016/j.jmatprotec.2005.01.007

Cited by 20 publications

(13 citation statements)

References 7 publications

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“…Other numerical methods include Finite Differences [13][14][15], Boundary Elements [16,17] and Finite Volumes [18,19]. However, numerical methods are computationally expensive in general, limiting their application to small plate geometries and simple laser trajectories, requiring full time history simulations.…”

Section: Laser Heating/cutting Simulationmentioning

confidence: 99%

Fast Simulation of Laser Heating Processes on Thin Metal Plates with FFT Using CPU/GPU Hardware

et al. 2020

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In flexible manufacturing systems, fast feedback from simulation solutions is required for effective tool path planning and parameter optimization. In the particular sub-domain of laser heating/cutting of thin rectangular plates, current state-of-the-art methods include frequency-domain (spectral) analytic solutions that greatly reduce the required computational time in comparison to industry standard finite element based approaches. However, these spectral solutions have not been presented previously in terms of Fourier methods and Fast Fourier Transform (FFT) implementations. This manuscript presents four different schemes that translate the problem of laser heating of rectangular plates into equivalent FFT problems. The presented schemes make use of the FFT algorithm to reduce the computational time complexity of the problem from O ( M 2 N 2 ) to O ( M N log ( M N ) ) (with M × N being the discretization size of the plate). The test results show that the implemented schemes outperform previous non-FFT approaches both in CPU and GPU hardware, resulting in 100 × faster runs. Future work addresses thermal/stress analysis, non-rectangular geometries and non-linear interactions (such as material melting/ablation, convection and radiation heat transfer).

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Section: Laser Heating/cutting Simulationmentioning

confidence: 99%

Fast Simulation of Laser Heating Processes on Thin Metal Plates with FFT Using CPU/GPU Hardware

et al. 2020

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“…Numerical methods are the most common simulation approach. Methods such as the Finite Differences Method (FDM) [8,9,10,11] and the Boundary Element Method (BEM) [12,13] have been used in the literature to study the thermal behaviour of sheet laser heating. However, these methods impose several numerical limitations such as dense rectangular grids in the case of FDM and non-sparse linear systems for BEM, requiring a high amount of computational resources even for simple problems.…”

Section: Literature Reviewmentioning

confidence: 99%

Fast Analytic Simulation for Multi-Laser Heating of Sheet Metal in GPU

et al. 2018

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Interactive multi-beam laser machining simulation is crucial in the context of tool path planning and optimization of laser machining parameters. Current simulation approaches for heat transfer analysis (1) rely on numerical Finite Element methods (or any of its variants), non-suitable for interactive applications; and (2) require the multiple laser beams to be completely synchronized in trajectories, parameters and time frames. To overcome this limitation, this manuscript presents an algorithm for interactive simulation of the transient temperature field on the sheet metal. Contrary to standard numerical methods, our algorithm is based on an analytic solution in the frequency domain, allowing arbitrary time/space discretizations without loss of precision and non-monotonic retrieval of the temperature history. In addition, the method allows complete asynchronous laser beams with independent trajectories, parameters and time frames. Our implementation in a GPU device allows simulations at interactive rates even for a large amount of simultaneous laser beams. The presented method is already integrated into an interactive simulation environment for sheet cutting. Ongoing work addresses thermal stress coupling and laser ablation.

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“…Flexible forming using plasma arc (FFUPA) is a newly developed technique, which produces deformation in metal sheet by thermal stress instead of external mechanical force. Without the requirement of mechanical contact, and hence without the need for hard tooling, it can significantly decrease the high cost and long lead time associated with the production of component specific tooling [2][3][4][5][6][7][8]. Male et al firstly demonstrated the feasibility of FFUPA in 2000 [2], then investigated the correlations between process parameters and bending angles of mild steel and stainless steel sheets during line heating, and studied the microstructural development in the heat affected zone [3].…”

Section: Introductionmentioning

confidence: 99%

“…Male et al firstly demonstrated the feasibility of FFUPA in 2000 [2], then investigated the correlations between process parameters and bending angles of mild steel and stainless steel sheets during line heating, and studied the microstructural development in the heat affected zone [3]. Based on the combination of experiments and numerical simulation, Xu et al conducted a systematical research on the forming mechanism, the rules of FFUPA affected by process parameters and material properties and scanning trajectory [4][5][6]. Wang et al studied the relationship between main process parameters and bending forming through experiments using the metal sheets of 1Cr18Ni9Ti and Q235 [7].…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Transient Deformation in the Flexible Forming of Laminated Composite Metal Sheets Using Plasma Arc

Song

Wang

et al. 2009

MSF

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A three-layer FEM model, based on the characteristics along the thickness direction of laminated composite metal sheets (LCMS), was developed to study the variation rules of transient deformation in the flexible forming of LCMS using plasma arc. Besides, the comparisons of the typical LCMS Q235A/1Cr13 and single layer metal sheet (SLMS) Q235A were performed. It indicates that the displacement of end point of SLMS is 0.076 mm larger than that of LCMS with the same process parameters. Moreover, the differences of X-axis plastic strain, Z-axis plastic strain along the thickness direction of LCMS decide the bending direction, the occurrence of the edge effect of LCMS during linear heating, respectively. Furthermore, Y-axis stresses of LCMS different layers undergo three dramatic changes with the maximum stress difference of 1.420×107 Pa, and the possible failure of interface delamination occurs in the bonding interface of Q235A and transition layer.

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A numerical simulation of temperature field in plasma-arc forming of sheet metal

Cited by 20 publications

References 7 publications

Fast Simulation of Laser Heating Processes on Thin Metal Plates with FFT Using CPU/GPU Hardware

Fast Simulation of Laser Heating Processes on Thin Metal Plates with FFT Using CPU/GPU Hardware

Fast Analytic Simulation for Multi-Laser Heating of Sheet Metal in GPU

Investigation of the Transient Deformation in the Flexible Forming of Laminated Composite Metal Sheets Using Plasma Arc

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