Numerical Analysis of Deep Drawing Process for Thermoplastic Composite Laminates

1997 ◽  
Vol 119 (3) ◽  
pp. 314-318 ◽  
Author(s):  
Shih-Wei Hsiao ◽  
Noboru Kikuchi
Keyword(s):  
Numerical Analysis ◽  
Deep Drawing ◽  
Fiber Orientation ◽  
Composite Laminates ◽  
Thermoplastic Composite ◽  
Woven Fabric ◽  
Drawing Process ◽  
Forming Process ◽  
Deep Drawing Process ◽  
Deformation Mechanics

A numerical analysis including flow, heat transfer and residual stress is developed to simulate the deep drawing process of composite laminates with woven fabric microstructures. The governing equations and material properties of thermoplastic composites at the forming temperature are obtained by the homogenization method based on the assumption of instantaneously rigid solid fibers suspended in a viscous non-Newtonian polymer melt. The processing rheology of the composites is characterized by a power-law constitutive model for this anisotropic, non-isothermal and shear thinning fluid. To simulate the thermoforming and cooling stages of the entire forming process, the three-dimensional finite element method incorporating a fiber orientation model of woven-fabric microstructures is developed. This global-local numerical methodology is capable of predicting macroscopic and microscopic deformation mechanics during the thermoforming process. As an illustration, a comparison between the fiber orientation prediction and experimental data for a deep drawn cup is presented.

Optimization of Deep Drawing Processes Using Statistical Design of Experiments

1996 ◽  
Author(s):  
Dietrich Bauer ◽  
Regine Krebs
Keyword(s):  
Mathematical Model ◽  
Analysis Of Variance ◽  
Orthogonal Array ◽  
Deep Drawing ◽  
Metal Forming ◽  
Drawing Process ◽  
Drawing Force ◽  
Forming Process ◽  
Deep Drawing Process ◽  
Metal Forming Process

Abstract For a deep drawing process some important controllable variables (factors) upon the maximum drawing force are analyzed to find a setting adjustment for these process factors that provides a very low force for the metal forming process. For this investigation an orthogonal array L18 with three-fold replication is used. To find the optimum of the process, the experimental results are analyzed in accordance with the robust-design-method according to Taguchi (Liesegang et. al., 1990). For this purpose, so-called Signal-to-Noise-ratios are calculated. The analysis of variance for this S/N-ratios leads to a mathematical model for the deep drawing process. This model allows to find the pressumed optimal settings of the investigated factors. In the following, a confirmation experiment is carried out by using these optimal settings. The maximum drawing force of the confirmation experiment does not correspond with the confidence interval, which was calculated by analysis of variance techniques. So the predicted optimum of the process does not lead to a metal forming process with very low deep drawing force. The comparison with a full factorial plan shows that there are interactions between the investigated factors. These interactions could not be discovered by the used orthogonal array. Thus the established mathematical model does not describe the relation between the factors and deep drawing force in accordance with the practical deep drawing conditions.

Investigation on Friction Coefficient Considering Al-Si Coating Layer Fracture of Boron Sheets in Hot and Cold Deep Drawing

2020 ◽  
Vol 846 ◽  
pp. 117-121
Author(s):  
Min Sik Lee ◽  
Jun Park ◽  
J.S.Suresh Babu ◽  
Chung Gil Kang
Keyword(s):  
Friction Coefficient ◽  
Deep Drawing ◽  
Deformation Behavior ◽  
Coating Layer ◽  
Surface Condition ◽  
Forming Limit ◽  
Boron Steel ◽  
Drawing Process ◽  
Forming Process ◽  
Deep Drawing Process

In this paper, hot and cold deep drawing processes are determined with direct deep drawing process and indirect deep drawing process. To predict the friction coefficient, the finite-element method, which can predict deformation behavior until the fracture of a blank sheet, was proposed using the forming limit diagram (FLD) curve. The effect of fracturing of the coating layer on the friction coefficient during the hot and cold deep drawing processes was investigated. The deformation behavior of the coating layer of the boron steel sheet that affects the friction coefficient in the hot and cold deep drawing processes was also proposed. A forming method that can control the surface condition of the formed product is further proposed by explaining the fracture of the coating due to the forming process.

Effect of the Blank-Holding Load on the Drawing Force in the Deep-Drawing Process of Cylindrical and Square Cups

2015 ◽  
Vol 760 ◽  
pp. 379-384 ◽  
Author(s):  
Lucian Lazarescu ◽  
Ioan Nicodim ◽  
Dan Sorin Comsa ◽  
Dorel Banabic
Keyword(s):  
Aluminum Alloy ◽  
Deep Drawing ◽  
The Other ◽  
Drawing Process ◽  
Drawing Force ◽  
Forming Process ◽  
Deep Drawing Process ◽  
Steel Sheets ◽  
Other Hand ◽  
Blank Holding Force

In this study, the influence of the blank-holding force (BHF) on the drawing force (DF) in the deep-drawing process of cylindrical and square cups has been investigated experimentally. For this purpose, different constant and variable BHFs have been applied to AA6016-T4 aluminum alloy and DC04 steel sheets during the forming process. It has been observed that an increased constant BHF leads to an increase of DF. On the other hand, the variable BHF approach, in which the BHF decreases in six steps throughout the punch stroke, reduces the DF.

Effect of Blank Holder Force with Low Frequency Vibration Technique in Circular-Cup Deep-Drawing Using AZ31 Magnesium Alloy Sheet

2011 ◽  
Vol 383-390 ◽  
pp. 2785-2789
Author(s):  
Naoki Horiike ◽  
Shoichiro Yoshihara ◽  
Yoshitaka Tsuji ◽  
Yusuke Okude
Keyword(s):  
Deep Drawing ◽  
Low Frequency ◽  
Lubricating Oil ◽  
Drawing Process ◽  
Blank Holder Force ◽  
Forming Process ◽  
Blank Holder ◽  
Deep Drawing Process ◽  
Low Frequency Vibration ◽  
Friction Performance

In the deep-drawing process, the application of low-frequency vibration to the blank material has recently been focused on with the aim of improving the friction performance between the die and the blank material. A servo-controlled press machine is suitable for applying low-frequency vibration to the blank during the deep-drawing process, because the punch speed and blank holder force (BHF) are easily controlled as process parameters by using the servo motors. In this study, a BHF with low-frequency vibration was proposed as a technique for improving deep-drawability, which is mainly affected by the friction performance and the lubricant condition. We found that the friction performance between the blank surface and the blank holder was decreased in the case of a BHF with low-frequency vibration since the lubricating oil rapidly flowed into the clearance during the forming process. Furthermore, for a BHF with low-frequency vibration, the punch force and the deformation resistance were lower than those in a deep-drawing test without low-frequency vibration.

The Analysis of Multistage Deep Drawing of AA5754 Aluminum Alloy

2010 ◽  
Vol 55 (4) ◽  
pp. 1173-1184 ◽  
Author(s):  
M. Paćko ◽  
M. Dukat ◽  
T. Śleboda ◽  
M. Hojny
Keyword(s):  
Aluminum Alloy ◽  
Numerical Analysis ◽  
Numerical Simulations ◽  
Contact Surface ◽  
Deep Drawing ◽  
Material Flow ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Side Walls ◽  
Good Agreement

The Analysis of Multistage Deep Drawing of AA5754 Aluminum AlloyThis work is focused on the multistage deep drawing of AA5754 aluminum alloy box-type part with flange. Both experimental and numerical analysis were performed in this study to predict causes of contraction and cracking occurring in deformed product in respect to the changes of friction conditions on tool-drawn part contact surface. The numerical simulations were performed using eta/DYNAFORM software and LS-DYNA® solver. The research showed, that the results of the simulation are in very good agreement with the results of the real multistage deep drawing processes. Moreover, this study showed, that proper conditions of friction on the tool-drawpiece contact surface is crucial for the correctness of the analyzed deep drawing process. Too large friction can restrict the material flow, particularly along the edge connecting the bottom and side-walls of the drawpiece, causing wrinkling and cracking.

Experimental Study of the Small Lubrication Holes on the Die Shoulder on the Formability in Cylindrical Cup Deep-Drawing

2010 ◽  
Vol 37-38 ◽  
pp. 428-431
Author(s):  
Yu Qing Shi
Keyword(s):  
Deep Drawing ◽  
Mechanical Characteristics ◽  
Experimental Methods ◽  
Sheet Forming ◽  
Drawing Process ◽  
Forming Process ◽  
Deep Drawing Process ◽  
Forming Quality ◽  
Forming Technology ◽  
Cylindrical Cup

Wrinkling and tearing are major defects that usually occur in the deep-drawing process. This study presents a new sheet forming technology, together with machining small lubrication holes on the die shoulder. Deep drawing process of cylindrical cups with flange is investigated. Mechanical characteristics of die shoulder with small lubrication holes in deep drawing are analyzed. Numerical simulation and experimental methods are used to determine the influence on formability of machining small lubrication holes on the die shoulder. The results show that this new sheet forming process can improve formability and forming quality.

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