Analysis and Control of Twist Defects of Aluminum Profiles with Large Z-Section in Roll Bending Process

Wang, Anheng; Xue, Hongqian; Bayraktar, E.; Yang, Yu; Saud, Shah; Chen, Peng

doi:10.3390/met10010031

Cited by 10 publications

(5 citation statements)

References 22 publications

(22 reference statements)

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“…The tested gondola is made of steel and aluminum alloys. As part of the fatigue tests, the entire structure is verified [14], and all elements, regardless of the material of manufacture, are subjected to visual tests. The manufacturer was not obliged to provide…”

Section: Research Objectmentioning

confidence: 99%

Experimental Interpretation of the Provisions of EN 13796-3 for Fatigue Testing of Cableway Gondolas

Bednarz¹,

Bieniek²,

Kołodziejczyk³

et al. 2023

Preprint

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Section: Research Objectmentioning

confidence: 99%

Experimental Interpretation of the Provisions of EN 13796-3 for Fatigue Testing of Cableway Gondolas

Bednarz¹,

Bieniek²,

Kołodziejczyk³

et al. 2023

Preprint

View full text Add to dashboard Cite

show abstract

“…The tested gondola is made of steel and aluminum alloys. As part of the fatigue tests, the entire structure is verified [30], and all elements, regardless of the material of manufacture, are subjected to visual tests. The manufacturer was not obliged to provide detailed information about the materials of which the tested gondola is made.…”

Section: Research Objectmentioning

confidence: 99%

Experimental Interpretation of the Provisions of EN 13796-3 for Fatigue Testing of Cableway Gondolas

Bednarz

Bieniek²,

Kołodziejczyk

et al. 2023

ASI

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This article presents an experimental approach to fatigue testing of cableway gondolas, carried out in accordance with the EN 13796-3 standard. Due to the limitations of the aforementioned regulations and the lack of clarity in their content, when designing and conducting fatigue tests of gondolas, there is a need to find solutions that meet the normative requirements, while ensuring the cost-effectiveness of the tests. The work presents the method of loading, receiving the degrees of freedom, the methodology of gondola strength verification and additional suggestions allowing for the satisfactory preparation of a plan of fatigue tests and their implementation. The paper shows problems and ways to solve it, what may occur during cableway gondolas fatigue test design. In addition, the work contains an extensive description and methodology for conducting research verifying the elastic and permanent deformation of the structure, using digital image correlation (DIC). The results obtained by using this method make it possible to unambiguously determine the degree of structure deformation while maintaining high accuracy and repeatability of measurements at many points of the structure. Following the presented tests, it was possible to correctly carry out fatigue tests of the nacelle in a satisfactory time (about 8 weeks), perform 5 million load cycles and verify the integrity of the structure. The presented results show the effectiveness of the adopted design assumptions and indicate the process that guarantees the correctness of the conducted fatigue tests. The prepared study may be the basis for further full-scale fatigue tests. The research object is a 6-seater gondola designed by TRANSSYSTEM S.A.

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“…Additionally, it enables a more accurate analysis of the laws and relationships among variables in the forming process. Consequently, this method has found wide application in various fields of profile roll-bending analysis [23], and it is regarded as the most effective approach for profile bending research [24,25]. Based on this, a dynamic finite element model of the four-roller roll-bending process was developed using the finite element software ABAQUS.…”

Section: Mechanical Property Testing Of 6063-t5 Aluminum Alloymentioning

confidence: 99%

Design of Z Profile Roller Tooling and Research on Roller Clearance

2023

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In metal processing, bending forming is widely applied in various fields. To prevent excessive surface scratching and heavy indentation on the profiles, which can negatively affect the surface quality, it is often necessary to determine the clearances between the rollers and the upper and lower surfaces of the profiles using experimental methods. However, this experimental approach not only results in material waste but also fails to determine the optimal clearance value. Therefore, orthogonal experiments were conducted to design different clearances between the rollers and the upper and lower surfaces of the profiles to mitigate the issues of excessive surface scratching and poor surface quality during the bending forming process of large-section Z-profiles. Finite element simulation was employed to simulate the different experiments, and a range analysis was performed on the experimental results to obtain the optimal clearance value. The obtained results fall within the range of results obtained from traditional experimental methods, indicating its consistency with actual practice, higher accuracy, and scientific rigor compared with experimental methods. Furthermore, the roller tooling design was revised based on the optimal clearance value for the profile processing. The experimental results demonstrate that the surface quality of the profiles processed with optimal clearance is superior to those processed without it. Additionally, this study presents a comprehensive methodology for roller tooling design and investigates the influence of different loading modes on the local wrinkling deformation of the profiles.

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Analysis and Control of Twist Defects of Aluminum Profiles with Large Z-Section in Roll Bending Process

Cited by 10 publications

References 22 publications

Experimental Interpretation of the Provisions of EN 13796-3 for Fatigue Testing of Cableway Gondolas

Experimental Interpretation of the Provisions of EN 13796-3 for Fatigue Testing of Cableway Gondolas

Experimental Interpretation of the Provisions of EN 13796-3 for Fatigue Testing of Cableway Gondolas

Design of Z Profile Roller Tooling and Research on Roller Clearance

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