Browsing by Subject "numerical model"
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Item An Experimental and Numerical Investigation of the Steady State Forces in Single Incremental Sheet Forming(2012-10-19) Nair, MaheshIncremental sheet forming process is a relatively new method of forming which is increasingly being used in the industry. Complex shapes can be manufactured using this method and the forming operation doesn't require any dies. High strains of over 300 % can also be achieved. Incremental sheet forming method is used to manufacture many different components presently. Prototype examples include car headlights, tubs, train body panels and medical products. The work done in the thesis deals with the prediction of the steady state forces acting on the tool during forming. Prediction of forces generated would help to design the machine against excessive vibrations. It would help the user to protect the tool and the material blank from failure. An efficient design ensures that the tool would not get deflected out of its path while forming, improving the accuracy of the finished part. To study the forces, experiments were conducted by forming pyramid and cone shapes. An experimental arrangement was set up and experimental data was collected using a data acquisition system. The effect that the various process parameters, like the thickness of the sheet, wall angle of the part and tool diameter had on the steady state force were studied. A three dimensional model was developed using commercial finite element software ABAQUS using a new modeling technique to simulate the deformation of the sheet metal blank during incremental sheet forming. The steady state forces generated for any shape, with any set of parameters used, could be predicted using the numerical model. The advantage of having a numerical model is that the forces can be predicted without doing experiments. The model was used to predict the steady state forces developed during forming of pyramid and cone shapes. The results were compared and were seen to be reasonably close to the experimental results. Later, the numerical model was validated by forming arbitrary shapes and comparing the value obtained from simulations to the value of the measured steady state forces. The results obtained from the numerical model were seen to match very well with the experimental forces for the new shapes. The numerical model developed using the new technique was seen to predict forces to a reasonable extent with less computational time as compared to the models currently available.Item Near-Field Sediment Resuspension Measurement and Modeling for Cutter Suction Dredging Operations(2011-02-22) Henriksen, John ChristopherThe sediment resuspension and turbidity created during dredging operations is both an economical and environmental issue. The movement of sediment plumes created from dredging operations has been predicted with numerical modeling, however, these far-field models need a ?source term? or near-field model as input. Although data from field tests have been used to create near-field models that predict the amount of material suspended in the water column, these results are skewed due to limitations such as non-uniform sediment distributions, water currents, and water quality issues. Laboratory investigations have obtained data for turbidity during dredging operations, but these results do not take advantage of the most contemporary testing methods. The purpose of this dissertation is to provide an estimation of turbidity created during a cutter suction dredging operation. This estimation was facilited by the development of resuspension measurement and data acquisition techniques in a laboratory setting. Near-field turbidity measurements around the cutter head were measured in the Haynes Coastal Engineering Laboratory at Texas A&M University. The laboratory contains a dredge/tow tank that is ideal for conducting dredging research. A dredge carriage is located in the dredge/tow tank and is composed of a carriage, cradle, and ladder. Acoustic Doppler Velocimetry (ADV) and Optical Backscatter Sensor (OBS) measurements were taken at specific points around the cutter head. The variables of suction flow rate, cutter speed, and the thickness of cut were investigated to understand their specific effect on turbidity generation and turbulence production around the cutter head. A near-field advection diffusion model was created to predict resuspension of sediment from a cutter suction dredge. The model incorporates the laboratory data to determine the velocity field as well as the turbulent diffusion. The model is validated with laboratory testing as well as field data. Conclusions from this research demonstrate undercutting consistently produced larger point specific turbidity maximum than overcutting in the laboratory testing. An increase in suction flow rate was shown to increase production and decrease turbidity around the cutter head. In general, an increase in cutter speed led to an increase in turbidity. The thickness of cut produced less resuspension for a full cut versus a partial cut. Data for a ?shallow cut? also produced less turbidity generation than partial cuts. The numerical model was compared to all laboratory testing cases as well as the Calumet Harbor and New Bedford cutter resuspension data and produced suitable MRA values for all tests. The numerical model produced higher point specific regions of turbidity for undercutting but produced larger mean values of turbidity for overcutting.