scholarly journals A new approach for dry metal forming: CO2 as volatile lubrication in combination with hard and low friction coatings

2018 ◽  
Vol 190 ◽  
pp. 14012
Author(s):  
Georg Umlauf ◽  
Henning Hasselbruch ◽  
Jan Hinnerk Henze ◽  
Jakob Barz ◽  
Andreas Mehner
Keyword(s):  
Tool Wear ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Coating System ◽  
Hybrid Technology ◽  
Dry Process ◽  
Novel Approach ◽  
The One

Nowadays, it is more important than ever to meet the increasing technical and statutory requirements and to develop new process strategies. In sheet metal forming the low consumption of oil lubrication gets an increasingly important role. The aim in sheet metal forming is to reduce the amounts of lubricants. In the long term, the future sheet metal processing should be able to completely dispense without mineral oil-containing lubricants. Two promising approaches for a dry process design are combined in this paper for the first time and the fundamental feasibility of this new hybrid technology is shown. On the one hand, a novel approach for temporary lubrication of deep-drawing processes with CO2 as a volatile medium is used. On the other hand, it is supported by the application of an additional hard coating system such as a silicon nitride (Si3N4) or tungsten doped a-C:H multilayered (Cr/CrNx/a-C:H:W/a-C:H) coating system to further reduce tool wear and wear debris of the formed sheets made of DC04 (mat. no.: 1.0338). The results show a low coefficient of friction and reduced wear. Especially for the carbon coating system, there is minor tool wear at a higher surface pressure. By means of the graphite constituent, even a smoothening of the roughness peaks can be recorded. The next step would be the implementation of this hybrid technology on a tool for deep drawing a rectangular cup.

Influence of Stamping Tool Fixation on Vibrations Using Specific Bolt Setups

2016 ◽  
Vol 1140 ◽  
pp. 353-360 ◽  
Author(s):  
Dominik Kraus ◽  
Johannes Hohmann ◽  
Stephan Wehnes ◽  
Peter Groche
Keyword(s):  
Tool Wear ◽  
Sheet Metal ◽  
Process Optimization ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
The Other ◽  
Tool Vibration ◽  
Part Quality ◽  
The One ◽  
Cutting Processes

In sheet metal forming, the fixation of tools in presses has not been considered to be variable for process optimization yet. Every clamping point fixes the tool. Tool areas without a fixation point have a vertical degree of freedom, respectively. Against this background, it seems to be evident that the kind of tool fixation can influence its static and dynamic beahviour. In shear cutting processes, tool vibration is an important phenomenon, as it affects tool wear on the one hand and influences part quality on the other hand. In this paper, a methodology for influencing the tool vibration by specific setups of the clamping situation is introduced.

Multi-Step Forward Finite Element Method for the Numerical Simulation of Sheet Metal Forming

2011 ◽  
Vol 474-476 ◽  
pp. 251-254
Author(s):  
Jian Jun Wu ◽  
Wei Liu ◽  
Yu Jing Zhao
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Mapping Method ◽  
Constitutive Relationship ◽  
Element Method

The multi-step forward finite element method is presented for the numerical simulation of multi-step sheet metal forming. The traditional constitutive relationship is modified according to the multi-step forming processes, and double spreading plane based mapping method is used to obtain the initial solutions of the intermediate configurations. To verify the multi-step forward FEM, the two-step simulation of a stepped box deep-drawing part is carried out as it is in the experiment. The comparison with the results of the incremental FEM and test shows that the multi-step forward FEM is efficient for the numerical simulation of multi-step sheet metal forming processes.

In-Process Visualisation for Deformation Monitoring and Analysis of Sheet Metal Forming Processes

2013 ◽  
Vol 677 ◽  
pp. 384-387 ◽  
Author(s):  
Wai Kei Ricky Kot ◽  
Luen Chow Chan
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Deformation Process ◽  
Deformation Monitoring ◽  
Displacement Sensor ◽  
Laser Displacement Sensor ◽  
Profile Data ◽  
Profile Change

In this paper, a visualisation system will be discussed that can be used to capture the deformation profile of the sheet blank during sheet metal forming processes, such as deep drawing and shape forming. The visualisation system utilizes a 2D laser displacement sensor for deformation profile acquisition. The sensor is embedded in the die and the laser propagates through the die to detect the profile change of the specimen concealed in the die during operation. The captured profile data will be collected, manipulated and transferred to a monitor for display via a controller. This visualisation of the deformation profile will provide engineers and researchers with an intuitive means of analysing and diagnosing the deformation process during sheet metal forming.

Mg sheet metal forming: Lessons learned from deep drawing Li and Y solid-solution alloys

JOM ◽  
2006 ◽  
Vol 58 (5) ◽  
pp. 62-69 ◽  
Author(s):  
Sean R. Agnew ◽  
Jeremy W. Senn ◽  
Joseph A. Horton
Keyword(s):  
Solid Solution ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Lessons Learned

Off-Line Testing of Tribo-Systems for Sheet Metal Forming Production

2014 ◽  
Vol 966-967 ◽  
pp. 3-20 ◽  
Author(s):  
Niels Bay ◽  
Ermanno Ceron
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Normal Pressure ◽  
Environmentally Benign ◽  
Interface Pressure ◽  
Test Conditions ◽  
Interface Contact ◽  
Very High

Off-line testing of new tribo-systems for sheet metal forming production is an important issue, when new, environmentally benign lubricants are to be introduced. To obtain useful results it is, however, vital to ensure similar conditions as in the production process regarding the main tribo-parameters, which are tool/workpiece normal pressure, sliding length, sliding speed and interface contact temperature. The paper describes a generic methodology for such tests exemplified on an industrial, multistage deep drawing example, where deep drawing is followed by two successive re-drawing operations leading to very high tool/workpiece interface pressure and temperature in the second re-draw. Under such conditions only the best lubricant systems work satisfactory, and the paper shows how the performance of different tribo-systems in production may be predicted by off-line testing combined with numerical modelling in order to ensure proper test conditions.

A Novel Approach for Transversely Anisotropic 2D Sheet Metal Forming Simulation

2011 ◽  
Vol 347-353 ◽  
pp. 3939-3945
Author(s):  
Jin Yan Wang ◽  
Ji Xian Sun
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Yield Function ◽  
Plane Stress Condition ◽  
Hill Model ◽  
Shell Elements ◽  
Forming Simulation ◽  
Novel Approach ◽  
Transversely Anisotropic

In most FEM codes, the isotropic-elastic & transversely anisotropic-elastoplastic model using Hill's yield function has been widely adopted in 3D shell elements (modified to meet the plane stress condition) and 3D solid elements. However, when the 4-node quadrilateral plane strain or axisymmetric element is used for 2D sheet metal forming simulation, the above transversely anisotropic Hill model is not available in some FEM code like Ls-Dyna. A novel approach for explicit analysis of transversely anisotropic 2D sheet metal forming using 6-component Barlat yield function is elaborated in detail in this paper, the related formula between the material anisotropic coefficients in Barlat yield function and the Lankford parameters are derived directly. Numerical 2D results obtained from the novel approach fit well with the 3D solution .

Advances in Plastic Anisotropy and Forming Limits in Sheet Metal Forming

2016 ◽  
Vol 138 (9) ◽  
Author(s):  
Dorel Banabic
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Constitutive Modeling ◽  
Metal Forming ◽  
Plastic Anisotropy ◽  
Forming Limit ◽  
Simulation Tools ◽  
The One ◽  
Forming Limit Curves

In the last decades, numerical simulation has gradually extended its applicability in the field of sheet metal forming. Constitutive modeling and formability are two domains closely related to the development of numerical simulation tools. This paper is focused, on the one hand, on the presentation of new phenomenological yield criteria developed in the last decade, which are able to describe the anisotropic response of sheet metals, and, on the other hand, on new models and experiments to predict/determine the forming limit curves.

Advances in Plastic Anisotropy and Forming Limits in Sheet Metal Forming

2015 ◽  
Author(s):  
Dorel Banabic
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Plastic Anisotropy ◽  
Constitutive Modelling ◽  
Forming Limit ◽  
Simulation Tools ◽  
The One ◽  
Forming Limit Curves

In the last decades, numerical simulation has gradually extended its applicability in the field of sheet metal forming. Constitutive modelling and formability are two domains closely related to the development of numerical simulation tools. This paper is focused, on the one hand, on the presentation of new phenomenological yield criteria developed in the last decade, which are able to describe the anisotropic response of sheet metals, and, on the other hand, on new models and experiments to predict/determine the forming limit curves.

scholarly journals Modelling real contact areas caused by material straining effects in sheet metal forming simulation

2021 ◽  
Author(s):  
Peter Essig ◽  
Mathias Liewald ◽  
Maximilian Burkart ◽  
Maxim Beck
Keyword(s):  
Sheet Metal ◽  
Surface Pressure ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Sheet Metal Part ◽  
Metal Part ◽  
Forming Simulation ◽  
Contact Areas ◽  
Surface Pressure Distribution

Shortened product development processes in automotive industry combined with the upcoming lack of experts do challenge sheet metal part production fundamentally. Tryout time and manufacturing costs of large forming dies today are significantly influenced by their digitally supported engineering. The forming process by such tools is beside other influences is affected by elastic deformations of forming dies and press structure as well as contact areas between die and sheet metal part. In deep drawing such contact areas are influenced by the blank properties and the flange behavior in terms of thickening and thinning. Recent developments in sheet metal forming simulation do consider advanced friction models and structural modeling of die and press components improving simulation accuracy. Nevertheless thinning or thickening of sheet metal results into localized surface pressure distribution during deep drawing. For this reason, it is not sufficient to use the currently common practice of homogeneous surface pressure distribution in sheet metal forming simulation. In this respect, this paper presents a numerical approach for consideration of straining effects in the sheet metal part during forming operation. For this purpose, a systematic process improvement was developed in this paper to identify contact areas via a numeric simulation parameter. Validating the numerical investigation, a rectangle cup die is used, considering major strain. The main results of this contribution for that reason show how simulated contact areas can be estimated by reverse engineering of real forming parts. Hereby straining based contact areas lead to a novel contact area design in process planning, resulting in efficient die tryout.

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