In order to check the force analysis calculations,
one half of the shell was taken from pro-engineer
and inserted in Algor. Algor is a finite element
program used to analyze certain forces inflicted
on the tooling by meshing it and analyzing each
node separately. For this case, the tooling is one-half
of the Equal Channel Angular Press (ECAP) die shown
in Figure 1. The die is subjected to a force in
the –y direction at the 45 degree corner turn
in the channel. When the copper sample is pressed
through, the channel will also feel a pressure force
throughout the nitride surface. The forces occurring
can be seen below also in Figure 1.
Figure 4.3: Half Shell of
the die tooling and the forces applied at the specified
nodes.
Blue Arrows = normal force of 6250lbf (-y)
Yellow Arrows=surface pressure forces of 2179lbf/in^2
(x.y.z)
Red Triangles= Surface constraints due to the bolts
and press (x,y,z)
From this force setup the analysis was run in Algor
and the data was analyzed. A test of the stress
was taken at each node in order to determine if
the tooling would hold up under the forces. The
material used in the test was Inconel 718, which
obtained a maximum yield stress of 179,000psi.The
results of the analysis is shown for the Von Mises
Stress below in figure 2. According to the results
the die will withstand the loading applied by the
press.
Figure 4.4: The Von Mises Stresses Inflicted on
the die by the forces applied from the copper sample
and press
The displacement was also analyzed in order to make
sure the deformation would remain in the elastic
region. Since the die will be subjected to many
sample tests the die had to remain within this region
to prevent permanent deformation. The displacement
maximum at .00162 remains within design constraints.
Figure 3 below shows the displacement at each node.
Figure 4.5: The displacement
caused by the forces applied to the die.
From the Algor analysis and results, it was determined
that the Inconel 718 will withstand the forces applied
by the experiment without deformation. These further
back-up our research and found data on Inconel 718.
