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Introduction
In this paper, the three above-mentioned simulations will be presented separately in order to make the
presentation easy to follow because each of them treats one specific science-technological problem. So the
presentation will begin with the case of a deep forming process of a double sink, then with the case of a
stadium roof under the wind effect. Finally the case of a ferro-concrete beam reinforced by the CFRP strips
will be treated.
Introduction
The manufacturing process of a double sink is composed of some technological steps, among them the
Deep Forming Step. The latest is, in the technological aspect, probably the most difficult step. Therefore
this step was chosen to be simulated with help of ANSYS software. The objective of this simulation is to
evaluate the influence of different technological factors and of blank’s material properties on the quality of
formed product. The obtained results should recommend the right choice of different manufacturing factors
to the designer/engineer, so permitting to achieve the required deepness of the sink without any damage in
the product.
Figure 1. Double sink and the working principle of deep forming process
mould blank-holder
blank
tool
The mapped meshing was created for the blank while the free meshing was implemented for the three other
pieces.
Three contact pairs are considered: tool/blank, blank-holder/blank and mould/blank. The Surface to Surface
contact is selected. Only the blank is considered as deformable while the three other pieces are considered
as rigid (non-deformable).
Initial configuration: The material of blank is the isotropic steel 1018 with bilinear kinematic hardening
behavior, and the failure strain εf = 0.75. The constant velocity load was applied until the product reaches
the required deepness (145mm) that means also that the forming process is single-stroke (continuous), and
the friction coefficient at contact surfaces was assumed to be 0.1.
With the above-defined configuration, the simulation was carried out with 4 different velocity of the tool:
1.45 m/s , 0.725 m/s , 0.322 m/s and 0.2 m/s. (corresponding to the active deep forming time: 0.1 s , 0.2 s ,
0.45 s and 0.725 s).
Then the simulation of a double-stroke deep forming process with a constant velocity: v = 0.322 m/s was
implemented.
In the next simulation, the friction coefficient at contact surfaces was chosen as 0.03 for single-stroke deep
forming with tool velocity v = 1.45 m/s.
The last simulation was carried out for the transversely anisotropic hardening steel 1010, with the friction
coefficient of 0.1, and by single-stroke forming with tool velocity: v = 0.322 m/s.
Figure 5. The effect of material properties of the blank on the achievable depth
Single stroke, friction coefficient = 0.1, v = 0.322 m/s
The Von-Mises equivalent plastic strain at the maximally achievable drawing depth
Introduction
Simulation of wind effect to structures plays an important role in different branches of the
industry: construction, automobile, aeronautics… The result of simulation should be used as load for
structure calculus/analysis or recommendation for aerodynamics purpose. In the here-considered case, we
have focused on the effect of the wind to a civil work’s structure. In ordinary practices, this wind effect
used to be provided from some National or Regional Design Standards for civil works. For more important
civil works, the physic model of the civil work (not 100 times smaller in dimension than its real structure in
order to achieve the required precision of simulation) must be created. This reduced model is then put in a
wind tunnel for experimentation; with the measured values provided by the wind tunnel’s measuring
equipment, the estimation of the wind effect on the real structure should be obtained. The later solution is
always time-consuming and very expensive; the cost of this physical modeling experimentation increases
quickly with the dimension and the complexity degree of the real structure and will become not-feasible at
all in some cases. With the rapid development of simulating CAE software recently, this problem should be
solved more and more efficiently nowadays. The example in this section will illustrate the powerfulness of
the ANSYS/CFX software in the simulating of the wind effect on a stadium roof.
The geometric model is represented in figure 6 and the finite element model (meshing) is represented in
figure 7. The mesh is composed of 92.088 elements and of 16.435 nodes.
The air in the zone of simulation is considered as turbulent and isothermal. The thermal transfer process is
simulated with the isothermal model.
The speed of wind at the inlet is assumed: v = 50 m/s. The relative pressure at the outlet is assumed to be
vanished (= 0). The condition “no shear” (speed = 0) is imposed at the symmetrical vertical plan and at the
“walls”: the roofs, the stands and the ground between the two stands. The “free shear” condition is imposed
at the free surface.
The pressure distribution at the symmetrical plan is plotted in figure 10, and the pressure distribution at the
stadium roof is represented in figure 11.
Figure 10. Pressure distribution at the Figure 11. Pressure distribution at the
symmetrical plan stadium roof
For better visualization of the wind flow applied on the structure, the streamline representation was used.
The velocity streamline is plotted in figure 12, and the pressure streamline is plotted in e pressure
distribution at the symmetrical plan is plotted in figure 13.
In order to estimate quantitatively the effect of the wind on the structure calculus of the roof, the pressure
due to the wind flow was transferred to surface pressure and applied directly on the roof. The displacement
contour is represented in the figure 14.
Figure 14. The displacement contour of the stadium roof under the pressure of wind
Introduction
The CFRP (Carbon Fiber Reinforced Plastics) strip, composed of carbon fibers and epoxy resin matrix, is
one commercial product of the Sika AG (Switzerland). This advanced material aims, among other
objectives, to replace the heavy steel plate in strengthening of existing ferro-concrete works. The main
advantages of this new method are the following:
∗ High tensile strength, capacity to reduce the propagation of cracks, light weight, availability in
any length.
* Water-resistant, also highly resistant to pollutant and other aggressive media in the environment of
the civil works, non-pollutant: conforming to the environmental regulations.
* Easy implementation, small amount of time and labor required, possibility to be used in the works
where the classical methods and materials are not applicable, for example in restoration/preservation of
ancient traditional constructions, or in the works having complex pipe systems...
In this section, one ferro-concrete beam reinforced by the CFRP strips (will be called later as “hybrid
structure”) will be simulated with ANSYS software in order to evaluate the contribution of those CFRP
strips to the resistance of the structure.
The displacement contour is plotted in figure 18. Due to the assumption of perfect bonding between the
ferro-concrete beam and the CFRP strip, the hybrid-beam is not peeled at this interface.
Conclusion
In this paper, the three simulations for three different cases were represented. The usefulness and
powerfulness of CAE software, namely the ANSYS software is proven.
Acknowledgement
This research is accomplished under the sponsorship of the VLIR-HUT Institutional University
Cooperation Program.
References
[1] Nguyen Viet Hung, Hoang Vinh Sinh, Thai The Hung, Luu Chi Hieu, “Numerical simulation of deep
drawing process for a double sink by using Ansys/LS-Dyna software”, Proceedings of the AUN/SEED-
Net 6th Field-wise Seminar on Manufacturing Engineering, Thailand, 10/2005.
[2] Bui Tran Trung, Nguyen Viet Hung, Bui Hai Le, “Simulation of wind effect to the structures”, Journal
of Science & Technology, vol. 55, in printing, Hanoi, 2006.
[3] Kachlakev, D.I. “Finite Element Analysis of a Historic Bridge Strengthened with FRP Laminates”,
paper 003, Third International Conference on Composites in Infrastructure, San Francisco, California,
June 10-12, 2002.