Sofiane SAAD - Academia.edu (original) (raw)

Papers by Sofiane SAAD

Research paper thumbnail of Fatigue design of the forged railway axles

Dans un contexte économique compétitif au niveau des coûts de fabrication et des matières premièr... more Dans un contexte économique compétitif au niveau des coûts de fabrication et des matières premières utilisées, un procédé innovant de conception et de fabrication des essieux ferroviaires est mis en place. Il consiste à forger des axes creux permettant une réduction significative de la consommation d’acier. Il s’agit d’analyser en quoi ces modifications de conception et de fabrication ont un impact sur la tenue en service et notamment sur la résistance aux sollicitations cycliques pouvant conduire à une rupture par fatigue. Suivant cet objectif, une chaîne numérique a été développée, allant de la simulation du procédé de fabrication jusqu’à l’analyse de la sollicitation cyclique en conditions de service. La première étape est la modélisation du procédé de forgeage afin de prédire les contraintes résiduelles et les déformations plastiques initiales. A partir de cet état de sollicitation, l’opération d’usinage et d’assemblage de la roue sur l’essieu, par frettage, est ensuite simulée ...

Research paper thumbnail of Modélisation de la tenue en fatigue d’essieux ferroviaires issus d’un procédé de forgeage

Dans un contexte economique competitif au niveau des couts de fabrication et des matieres premier... more Dans un contexte economique competitif au niveau des couts de fabrication et des matieres premieres utilisees, un procede innovant de conception et de fabrication des essieux ferroviaires est mis en place. Il consiste a forger des axes creux permettant une reduction significative de la consommation d’acier. Il s’agit d’analyser en quoi ces modifications de conception et de fabrication ont un impact sur la tenue en service et notamment sur la resistance aux sollicitations cycliques pouvant conduire a une rupture par fatigue. Suivant cet objectif, une chaine numerique a ete developpee, allant de la simulation du procede de fabrication jusqu’a l’analyse de la sollicitation cyclique en conditions de service. La premiere etape est la modelisation du procede de forgeage afin de predire les contraintes residuelles et les deformations plastiques initiales. A partir de cet etat de sollicitation, l’operation d’usinage et d’assemblage de la roue sur l’essieu, par frettage, est ensuite simulee ...

Research paper thumbnail of Modeling and Simulation of Tool Wear During the Cutting Process

Procedia CIRP, 2013

Experimental and analytic methods are still the main ways to investigate different cutting tool w... more Experimental and analytic methods are still the main ways to investigate different cutting tool wear types. Numerous developments of numerical methods and simulations, associated to the existence of more and more powerful computer make possible tool wear studies using FEM. The main purpose of this work is to present a new approach to predict tool wear progression during cutting operation. In particular, an energy approach, linking the tool wear volume with the energy dissipated by friction is used. In addition, the interaction between residual stresses induced by cutting and the variation of tool geometry due to wear's mechanisms is investigated. In order to carry out this study, it is presented the experimental measurements of the wear of the tool, in particular the lost volume during the cut. Numerical simulation of orthogonal cutting operation using the commercial FEM code ABAQUS/Explicit is employed.

Research paper thumbnail of Numerical Chain of Forging Railway Axle and Wheel Press Fitting Operation

Lecture Notes in Mechanical Engineering, 2015

In today’s competitive business environment, it has become increasingly important to reduce manuf... more In today’s competitive business environment, it has become increasingly important to reduce manufacturing and raw materials costs. For this purpose, an innovative process of design and manufacturing railway axles is developed. It is based on forging hollow axle which allows a significant reduction in steel consumption. In this work, we tried to analyse how these modifications induced by this new process and design impact on the residual stress field. For this particular study, a numerical chain has been developed going from the simulation of the hot upsetting manufacturing process of the railway axle with the explicit method, to the analysis of the cutting and the press fitting assembly operation. This study consists in modelling the forging process with the dynamic FEM in order to take into account the dynamic phenomena and predict the residual stress field and the initial plastic strain. Then the evaluation of the cutting operation of the upper axle surface and finally the simulation of assembling the wheel on the axle with a static model, to better estimate the stress relaxation and redistribution.

Research paper thumbnail of Development of a Numerical Chain to Optimize Railway Axles with Respect to Fatigue Damage

Key Engineering Materials, 2014

In today's competitive business environment, it has become increasingly important to reduce m... more In today's competitive business environment, it has become increasingly important to reduce manufacturing and raw materials cost. For this purpose, an innovative process of design and manufacturing railway axles is developed. It is based on forging hollow axles which allows a significant reduction in steel consumption. In this work, we tried to analyze how these modifications induced by this new process and design impact the service behavior and particularly the durability face to cyclic loadings that can lead to fatigue failure. In the present study, a numerical chain has been developed going from the simulation of the manufacturing process up to the analysis in fatigue. In the first step, the forging process is modeled in order to predict the residual stress field and the initial plastic strain. From this initial condition, the assembly operation of the wheel on the axle is simulated before the redistribution of stresses and strains under cyclic load. The final objective is to...

Research paper thumbnail of Electrical Driven Compressor – Vibration Correlation for PCB & Electronic Components

SAE Technical Paper Series

Electrical driven compressors (EDC) are mounted on the automotive driveline to compress refrigera... more Electrical driven compressors (EDC) are mounted on the automotive driveline to compress refrigerants in an automotive air conditioning system. The electrical power delivered by the battery is converted to mechanical power by an inverter and an electrical motor. The inverter is composed of a printed circuit board (PCB) with assembled electronic components. For the inverter part of the EDC, the vibration failures are predominant followed by thermal failures on electronic components. Hence robust methodology is necessary to improve the strength of the design under vibration environment through Finite Element Analysis. In this paper, a multi-fidelity methodology to validate automotive electronic components under harmonic loading through Finite Element Analysis is presented. This multi-fidelity methodology allows the risk of failure to be assessed at the earliest stages of product design, when changes are easy to make and have a low financial impact. The main focus is on the last stage o...

Research paper thumbnail of Fatigue design of the forged railway axles

Dans un contexte économique compétitif au niveau des coûts de fabrication et des matières premièr... more Dans un contexte économique compétitif au niveau des coûts de fabrication et des matières premières utilisées, un procédé innovant de conception et de fabrication des essieux ferroviaires est mis en place. Il consiste à forger des axes creux permettant une réduction significative de la consommation d’acier. Il s’agit d’analyser en quoi ces modifications de conception et de fabrication ont un impact sur la tenue en service et notamment sur la résistance aux sollicitations cycliques pouvant conduire à une rupture par fatigue. Suivant cet objectif, une chaîne numérique a été développée, allant de la simulation du procédé de fabrication jusqu’à l’analyse de la sollicitation cyclique en conditions de service. La première étape est la modélisation du procédé de forgeage afin de prédire les contraintes résiduelles et les déformations plastiques initiales. A partir de cet état de sollicitation, l’opération d’usinage et d’assemblage de la roue sur l’essieu, par frettage, est ensuite simulée ...

Research paper thumbnail of Modélisation de la tenue en fatigue d’essieux ferroviaires issus d’un procédé de forgeage

Dans un contexte economique competitif au niveau des couts de fabrication et des matieres premier... more Dans un contexte economique competitif au niveau des couts de fabrication et des matieres premieres utilisees, un procede innovant de conception et de fabrication des essieux ferroviaires est mis en place. Il consiste a forger des axes creux permettant une reduction significative de la consommation d’acier. Il s’agit d’analyser en quoi ces modifications de conception et de fabrication ont un impact sur la tenue en service et notamment sur la resistance aux sollicitations cycliques pouvant conduire a une rupture par fatigue. Suivant cet objectif, une chaine numerique a ete developpee, allant de la simulation du procede de fabrication jusqu’a l’analyse de la sollicitation cyclique en conditions de service. La premiere etape est la modelisation du procede de forgeage afin de predire les contraintes residuelles et les deformations plastiques initiales. A partir de cet etat de sollicitation, l’operation d’usinage et d’assemblage de la roue sur l’essieu, par frettage, est ensuite simulee ...

Research paper thumbnail of Modeling and Simulation of Tool Wear During the Cutting Process

Procedia CIRP, 2013

Experimental and analytic methods are still the main ways to investigate different cutting tool w... more Experimental and analytic methods are still the main ways to investigate different cutting tool wear types. Numerous developments of numerical methods and simulations, associated to the existence of more and more powerful computer make possible tool wear studies using FEM. The main purpose of this work is to present a new approach to predict tool wear progression during cutting operation. In particular, an energy approach, linking the tool wear volume with the energy dissipated by friction is used. In addition, the interaction between residual stresses induced by cutting and the variation of tool geometry due to wear's mechanisms is investigated. In order to carry out this study, it is presented the experimental measurements of the wear of the tool, in particular the lost volume during the cut. Numerical simulation of orthogonal cutting operation using the commercial FEM code ABAQUS/Explicit is employed.

Research paper thumbnail of Numerical Chain of Forging Railway Axle and Wheel Press Fitting Operation

Lecture Notes in Mechanical Engineering, 2015

In today’s competitive business environment, it has become increasingly important to reduce manuf... more In today’s competitive business environment, it has become increasingly important to reduce manufacturing and raw materials costs. For this purpose, an innovative process of design and manufacturing railway axles is developed. It is based on forging hollow axle which allows a significant reduction in steel consumption. In this work, we tried to analyse how these modifications induced by this new process and design impact on the residual stress field. For this particular study, a numerical chain has been developed going from the simulation of the hot upsetting manufacturing process of the railway axle with the explicit method, to the analysis of the cutting and the press fitting assembly operation. This study consists in modelling the forging process with the dynamic FEM in order to take into account the dynamic phenomena and predict the residual stress field and the initial plastic strain. Then the evaluation of the cutting operation of the upper axle surface and finally the simulation of assembling the wheel on the axle with a static model, to better estimate the stress relaxation and redistribution.

Research paper thumbnail of Development of a Numerical Chain to Optimize Railway Axles with Respect to Fatigue Damage

Key Engineering Materials, 2014

In today's competitive business environment, it has become increasingly important to reduce m... more In today's competitive business environment, it has become increasingly important to reduce manufacturing and raw materials cost. For this purpose, an innovative process of design and manufacturing railway axles is developed. It is based on forging hollow axles which allows a significant reduction in steel consumption. In this work, we tried to analyze how these modifications induced by this new process and design impact the service behavior and particularly the durability face to cyclic loadings that can lead to fatigue failure. In the present study, a numerical chain has been developed going from the simulation of the manufacturing process up to the analysis in fatigue. In the first step, the forging process is modeled in order to predict the residual stress field and the initial plastic strain. From this initial condition, the assembly operation of the wheel on the axle is simulated before the redistribution of stresses and strains under cyclic load. The final objective is to...

Research paper thumbnail of Electrical Driven Compressor – Vibration Correlation for PCB & Electronic Components

SAE Technical Paper Series

Electrical driven compressors (EDC) are mounted on the automotive driveline to compress refrigera... more Electrical driven compressors (EDC) are mounted on the automotive driveline to compress refrigerants in an automotive air conditioning system. The electrical power delivered by the battery is converted to mechanical power by an inverter and an electrical motor. The inverter is composed of a printed circuit board (PCB) with assembled electronic components. For the inverter part of the EDC, the vibration failures are predominant followed by thermal failures on electronic components. Hence robust methodology is necessary to improve the strength of the design under vibration environment through Finite Element Analysis. In this paper, a multi-fidelity methodology to validate automotive electronic components under harmonic loading through Finite Element Analysis is presented. This multi-fidelity methodology allows the risk of failure to be assessed at the earliest stages of product design, when changes are easy to make and have a low financial impact. The main focus is on the last stage o...