Teaching Curriculum System and Its Construction on the Course of “Stamping Forming Process and Die Design” Under the Background of Big Data

2020 ◽  
pp. 699-704
Author(s):  
Songqing Liu
Keyword(s):  
Big Data ◽  
Die Design ◽  
Forming Process ◽  
Teaching Curriculum

Semi-Enclosed Cold Forging Process Analysis and Progressive Die Design of CPU Fin

2008 ◽  
Vol 575-578 ◽  
pp. 174-179
Author(s):  
Juan Hua Su ◽  
Feng Zhang Ren ◽  
Lei Wang
Keyword(s):  
Production Efficiency ◽  
High Efficiency ◽  
Process Analysis ◽  
Die Design ◽  
Cold Forging ◽  
Forming Process ◽  
Element Analysis ◽  
Whole Process ◽  
Progressive Dies ◽  
Transfer Unit

This paper analyzes the forming process methods of fin used in CPU chip to emit heat. The whole process is blanking, the first forging forming, the second forging (sizing), and trimming. The chamfer design of CPU fin blank is simulated by finite element analysis. The optimized chamfer 1.6 mm is available. Semi-enclosed cold forging of progressive dies is put forward. The newly designed transfer unit is applied, which unifies the merit of high efficiency of the progressive dies and the high material-using ratio of the project die. Quick disassembly structure is designed and pins are used as quick disassembly pins by means of ball bearing bushing. The unique processing of the shearing scrap structure is adopted when designing the inverted trimming dies. Compared with the traditional die, the mechanization and electrization are realized to increase the production efficiency and get highly precise CPU fin.

scholarly journals Flexible Die Design and Springback Compensation Based on Modified Displacement Adjustment Method

2014 ◽  
Vol 6 ◽  
pp. 131253 ◽  
Author(s):  
Young-Ho Seo ◽  
Ji-Woo Park ◽  
Woo-Jin Song ◽  
Beom-Soo Kang ◽  
Jeong Kim
Keyword(s):  
Closed Loop ◽  
Three Dimensional ◽  
Loop System ◽  
Die Design ◽  
Manufacturing Cost ◽  
Closed Loop System ◽  
Forming Process ◽  
Element Analysis ◽  
Springback Compensation ◽  
Flexible Die

Springback in metal forming process often results in undesirable shape changes in formed parts and leads to deterioration in product quality. Even though springback can be predicted and compensated for through the theories or methodologies established thus far, an increase in manufacturing cost accompanied by a change in die shape is inevitable. In the present paper, it is suggested that the cost accompanied with springback compensation can be minimized while allowing the processing of various three-dimensional curved surfaces by using a flexible die composed of multiple punches. With the die being very flexible, the iterative trial-and-error method can be readily applied to compensate for the springback. Thus, repeated designing and redesigning of solid or matched dies can be avoided, effectively saving considerable time. Only some adjustments of punch height are required. Detailed designs of the flexible die as well as two core algorithms to control the respective punch heights are described in this paper. In addition, a closed-loop system for the springback compensation using the flexible die is proposed. The amount of springback was simulated by a finite element analysis and the modified displacement adjustment (DA) method as the springback compensation model was used in the closed-loop system. This system was applied to a two-dimensional quadratic shape problem, and its robustness was verified by an experiment.

scholarly journals Design of Hydraulic Bulging Die for Automobile Torsion Beam and Optimization of Forming Process Parameters

2021 ◽  
Vol 2021 ◽  
pp. 1-18
Author(s):  
Kefan Yang ◽  
Youmin Wang ◽  
Kexun Fu
Keyword(s):  
Friction Coefficient ◽  
Process Parameters ◽  
Orthogonal Experiment ◽  
Die Design ◽  
Molding Pressure ◽  
Hydraulic Pressure ◽  
Forming Process ◽  
Torsion Beam ◽  
Supporting Pressure ◽  
Hydraulic Bulging

The hydraulic bulging technology of tubes can provide hollow parts with special-shaped cross sections. Its manufacturing process can effectively improve material utilization and product accuracy and reduce the number and cost of molds. However, the hydraulic bulging process of parts is very complicated. The size of the tube blank, the design of the loading route, and the forming process parameters will have an effect on the molding quality. Closed tubular torsion automobile beam is considered as the research object to study hydraulic bulging die design and optimize forming process parameters. CATIA software is used to design torsion beam product structure and hydraulic bulging die. AMESim software is employed to design hydraulic synchronous control system for cylinders on both sides of the hydraulic bulging die. Mathematical control model is established and verified in Simulink software. DYNAFORM software is applied to conduct numerical simulation of hydraulic expansion. The supporting pressure, molding pressure, friction coefficient, and feeding quantity are taken as orthogonal experiment level factors. Maximum thinning and maximum thickening rates are taken as hydraulic pressure expansion evaluation indexes to complete the orthogonal experiments. Main molding process parameters are analyzed via orthogonal experiment results and optimized by employing the Taguchi method. Optimal hydraulic bulging parameters are obtained as follows: supporting pressure of 20 MPa, molding pressure of 150 MPa, feeding quantity of 25 mm, and friction coefficient of 0.075. Simulation analysis results indicate that the maximum thinning rate is equal to 9.013%, while the maximum thickening rate is equal to 16.523%. Finally, the design of hydraulic bulging die for torsion beam was completed, and its forming process parameters were optimized.

Applying 2k Factorial Design to Study on Parameters Affecting Springback of Forming of Advanced High Strength Steel Sheets (AHSS)

2017 ◽  
Vol 872 ◽  
pp. 83-88
Author(s):  
Ramil Kesvarakul ◽  
Chamaporn Chianrabutra ◽  
Watcharapong Sirigool
Keyword(s):  
Elastic Recovery ◽  
Weight Ratio ◽  
High Strength ◽  
Die Design ◽  
Statistical Experimental Design ◽  
Blank Holder Force ◽  
Forming Process ◽  
Blank Holder ◽  
Punch Radius ◽  
Springback Angle

Advanced high strength steels (AHSS) are widely used in the automotive industry due to their appropriate strength to weight ratio. This alloy has unique hardening behavior and variable unloading elastic modulus; however, the unavoidable obstacle of AHSS sheet metal forming is springback. The springback is a result of elastic recovery and residual stress. The aim of this study is to determine the proper process parameters enabling the reduction of the springback defects in AHSS forming process. This work was divided into two parts, regarding to the effects of numerical parameters and process parameter on forming AHSS. In this paper, a U-shape forming was used to examine the springback behaviors, such as springback angle, sidewall curl, and thickness, through an experiment. To achieve this purpose, 2k factorial statistical experimental design has been employed to investigate the parameters affecting the springback of forming in AHSS to find out the main effect in the springback reduction focusing on using as a guideline for die design. It showed that the blank holder force is the most influential parameter. The second is the punch radius. However, the blank holder force and punch radius is not simple to adjust in die design, the die radius becomes the important parameter to be used to reduce the springback angle.

Finite Element Simulation of the Yoke Spline under Hot Forging Process

2020 ◽  
Vol 982 ◽  
pp. 106-111
Author(s):  
Surasak Suranuntchai
Keyword(s):  
Finite Element ◽  
Hot Forging ◽  
Fem Simulation ◽  
Die Design ◽  
Forming Process ◽  
Element Simulation ◽  
Metal Forming Process ◽  
Automotive Part ◽  
Forging Die ◽  
Hot Forging Process

Nowadays, finite element method (FEM) has been widely used to forecast metal forming process, to analysis problems of workpiece, to decrease production cost, and to save time of die design. This work studied the use of FEM as a tool to design a hot forging die for producing an automotive part named Yoke Spline. The part was made from carbon steel grade S45CVL0. There are three processes to produce Yoke Spline, including the buster, rougher, and finisher processes. The objective of the study was to increase efficiency of production by 5%. To achieve this objective, it was necessary to design a new die in the buster process by using FEM to analyze the die size and shape. The new die must produce the workpieces without any defects. The defects regularly found in the forging workpieces are the dimension out of specification, the under filling, and the crack. The sizes of the buster upper die cover are the width and depth. The die width of 44.5, 46.5 and 49.5 millimeters and the die depth of 25, 28 and 31 millimeters were used in the hot forging simulation. From FEM simulation results, it was found that the die width of 46.5 millimeters and the die depth of 28 millimeters were the best to form workpieces without any defects. In summary, the simulation and experimental results were compatible.

Rheoforging of thin case for IT devices with optimal process parameters and new type die design

2013 ◽  
Vol 228 (6) ◽  
pp. 1021-1028
Author(s):  
Yong Phil Jeon ◽  
Amir Bolouri ◽  
Hyung Yoon Seo ◽  
Jong Deok Kim ◽  
Chung Gil Kang
Keyword(s):  
Mechanical Properties ◽  
Cell Phone ◽  
Processing Parameters ◽  
Die Design ◽  
Electromagnetic Stirring ◽  
Forming Process ◽  
Processing Technologies ◽  
Promising Tool ◽  
New Type ◽  
Semi Solid

The latest trend in the cell phone component industry to use aluminium and magnesium alloys has resulted in the advanced processing technologies. Semi-solid forming process that is advantageous for the mass production of thin parts with complex shapes have been of interest as a promising tool for near net-shape manufacturing. This study describes a semi-solid forming process for the development of a 1 mm-thick cell phone case by using the rheological material prepared by electromagnetic stirring equipment. Thus, a new type of die design for indirect rheoforging was proposed to efficiently control the primary α-Al phase particles in the thin part under rheological conditions. Their microstructure and mechanical properties were investigated and compared to parts produced without electromagnetic stirring. Those products fabricated by electromagnetic stirring had better mechanical properties and globular microstructures than those fabricated without electromagnetic stirring. Several processing parameters such as punch velocity (30 mm/s), punch pressure (75–250 MPa), stirring time (10 s), and solid fraction (0–20%) were used. The optimal condition that resulted in a defect-free component with the improved mechanical properties was explained and discussed.

Sheet Metal Forming Process Design Rules Development

2011 ◽  
Vol 473 ◽  
pp. 765-772
Author(s):  
Antonio del Prete ◽  
Gabriele Papadia ◽  
Teresa Primo
Keyword(s):  
Process Design ◽  
Process Variable ◽  
Complex Problem ◽  
Industrial Test ◽  
Thickness Ratio ◽  
Die Design ◽  
Design Development ◽  
Forming Process ◽  
Element Analysis ◽  
Constitutive Material

Finite element analysis (FEA) is a powerful tool to evaluate the formability of stamping parts during process and die design development procedures. However, in order to achieve good product quality and process reliability, FEA application has to be performed many times exploring different process parameters combinations. Meanwhile, it is very difficult to perform an exhaustive process design definition when many parameters play a fundamental role to define such a complex problem. So, under the needs of reduction in: design time, development cost and parts weight, there is an urgent need to develop and apply more efficient methods in order to improve the current design procedures. For a generic component it is clear how its shape, among several parameters, has a direct influence on its feasibility. Starting from this assumption, the authors have developed a new approach grouping components upon their shapes analyzing component formability within a given “component family”. Nowadays, it exists only a process designer “sensitivity” that produces a ranking upon shape/feasibility ratio. Having as reference industrial test cases, the authors have defined appropriate shape parameters in order to have dimensionless coefficients representative for the given geometries. In particular, the components have been classified using a parameters set defining similarity families: related to geometrical aspects and to constitutive material. From the geometrical point of view the following parameters have been defined: family name, shape factor, punch radius-thickness ratio, die radius-thickness ratio, while for the constitutive material a code has been defined. FEA has been extensively used in order to: define, investigate and validate each shape parameter with a proper comparison to the macro feasibility of the chosen component geometry. The feasibility configuration definition, for a given shape, has been made through an appropriate study of the influence of each process variable on the properly process performances.

Sheet Metals Forming Die Design Using Finite Element Analysis and the Taguchi Method

2014 ◽  
Vol 621 ◽  
pp. 195-201
Author(s):  
Surangsee Dechjarern ◽  
Maitri Kamonrattanapisut
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Friction Coefficient ◽  
Taguchi Method ◽  
Finite Element Model ◽  
Sheet Metal ◽  
Element Model ◽  
Die Design ◽  
Forming Process ◽  
Element Analysis

Sheet metal deep-draw die is primarily constructed with draw bead, which is then modified based on trial and error to obtain a successful forming without splitting. This work aims at a robust design of forming die using numerical analysis and the Taguchi method. A three dimensional elastoplastic finite element model of a sheet metal forming process of SPCEN steel has been successfully developed using the material flow stress obtained from the modified Erichsen cup test. The model was validated with the actual forming experiment and the results agreed well. The influence of draw bead parameters on splitting and thinning distributions were examined using the Taguchi method. Four parameters, namely the friction coefficient, draw bead height, radius and shoulder radius were investigated. The Taguchi main effect analysis and ANOVA results show that the height and shoulder radius of the draw bead are the most important factor influencing the thinning distribution. Applying the Taguchi method and using the minimum thinning percentage as the design criteria, the optimum die design was identified as height, radius, shoulder radius and the friction coefficient of 4, 8, 8 mm and 0.125 respectively. The verified finite element model using the optimum die design was conducted. The predicted Taguchi response was within 5.9% from finite element analysis prediction. The improvement in the reduction of thinning percentage was 22.35%.

A Review of Liquid Forging Process

2013 ◽  
Vol 690-693 ◽  
pp. 2275-2279 ◽  
Author(s):  
Xi Na Huang ◽  
Zhi Ping Zhong ◽  
Wei Wang ◽  
Feng Jiao Li ◽  
De Hua Qiu ◽  
...  
Keyword(s):  
Liquid Metal ◽  
New Technology ◽  
Die Casting ◽  
Die Design ◽  
Forming Process ◽  
High Quality ◽  
Simulation And Optimization ◽  
Forging Process ◽  
Bulk Forming ◽  
Plastic Forming

Liquid forging is a new technology of plastic forming. It is a kind of bulk forming process with liquid metal with high-quality and efficiency and it has the characteristics of both die casting and forging. This paper will discuss the liquid forging process, die design, simulation and optimization of liquid forging [1].

Experimental modeling of fluid pressure in hydrostatic forming for cylindrical product

2020 ◽  
Vol 34 (22n24) ◽  
pp. 2040158
Author(s):  
Nguyen Thi Thu ◽  
Nguyen Dac Trung
Keyword(s):  
Fluid Pressure ◽  
Regression Function ◽  
Die Design ◽  
Design Calculation ◽  
Forming Process ◽  
Blank Holder ◽  
Forming Technology ◽  
Input Parameters ◽  
Function Relationship ◽  
And Control

Forming fluid pressure is an important technological parameter that determines whether a product can be accurately formed according to the size and profile of the die in hydrostatic forming technology. The expected value of this parameter is often very high because it acts as the punch in forming complex products from sheet metal. However, it is difficult to achieve high values because the forming fluid pressure depends on the ability to hold high pressure of equipment system and input parameters including the blank holder pressure, the depth of die, the thickness of workpiece. Moreover, it is also necessary to have a mathematical model for this parameter to facilitate the calculation and control of the forming process. In order to solve the above problems, this paper will indicate a simple way to avoid the pressure drop during forming process, and establish a regression function relationship between the forming fluid pressure for typical cylindrical product and input parameters above by experimental research method. The results contribute to die design, calculation and control of process parameters to facilitate shaping thin shell products in actual hydrostatic forming technology.

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