Evaluation of Stamping Lubricants in Forming Galvannealed Steels for Industrial Application

2011 ◽  
Vol 133 (6) ◽  
Author(s):  
Soumya Subramonian ◽  
Nimet Kardes ◽  
Yurdaer Demiralp ◽  
Milan Jurich ◽  
Taylan Altan
Keyword(s):  
Preliminary Test ◽  
Work Piece ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Deep Draw ◽  
Fe Simulations ◽  
Water Based ◽  
The Coefficient Of Friction ◽  
Synthetic Water

Lubrication is one of the process variables that affect the quality of stamping sheet materials. Using a good lubricant can significantly reduce scrap rate and/or improve the quality of stamping. In this study, different types of lubricants were evaluated using strip draw test (SDT) and deep draw test (DDT) for stamping of galvannealed steel sheets. Finite element (FE) simulations were carried out to determine the coefficient of friction at tool-work piece interface during deep drawing under different lubrication conditions and blank holder forces. Flow stress data of materials under biaxial load which are used in FE simulations are obtained by viscous pressure bulge tests. SDT was used as a preliminary test to evaluate the relative performance of the lubricants. Lubricants that showed good performance in this test were tested using DDT. Dimensions of the formed strips and cups and the maximum applicable blank holder force to draw parts without fracturing were the criteria used for evaluation of lubricants in both tests. In general, it was possible to form cups with higher blank holder force when synthetic/water-based lubricants were applied to the sheet. In conclusion, evaluated synthetic/water-based lubricants had better lubricity than petroleum-based lubricants.

Experimental Researches upon Changes of a Pipe's Roughness after Hydroformation

2013 ◽  
Vol 371 ◽  
pp. 111-115
Author(s):  
Bogdan Constantin Vaceanu ◽  
Gheorghe Nagit ◽  
Vasile Huian
Keyword(s):  
Surface Roughness ◽  
Tube Hydroforming ◽  
Work Piece ◽  
Copper Pipe ◽  
Work Area ◽  
The Coefficient Of Friction ◽  
Hydroforming Process ◽  
Aluminum Pipe ◽  
Experimental Researches

Surface roughness was studied in the tube hydroforming process, considering the quality of the material and the coefficient of friction between the work piece and die. Other researchers have studied the surface roughness to the front of an aluminum pipe [. The aim of this work was to analyze changes in a copper pipe roughness occurred after hydroforming process with fluid. Effects of changing roughness were studied, following the deformation of the material in the work area and roughness changes occurring in the material flow. After achieving hydroforming process, the surface roughness was measured by electron microscopy SEM in different areas of the hydro formed tube. After hydroforming process, an increase of surface roughness in connection areas of the mold to the curvature and the transverse direction of the pipe.

The Impact Analysis of Stamping Process Factors Based on Dynaform

2013 ◽  
Vol 712-715 ◽  
pp. 642-646
Author(s):  
Zhen Gang He ◽  
Yan Ping Zheng ◽  
Gai Yan
Keyword(s):  
Quality Evaluation ◽  
Impact Analysis ◽  
Simulation Analysis ◽  
Blank Holder Force ◽  
Forming Process ◽  
Blank Holder ◽  
Stamping Process ◽  
The Coefficient Of Friction ◽  
Process Factors ◽  
The Impact

Combining with practical needs in production, it carried out the numerical simulation analysis of automobile beam stamping forming process based on Dynaform in this paper. According to quality evaluation index of forming parts, it analyzed the effect of variation of blank holder force, the stamping speed, the coefficient of friction and draw bead on stamping quality. It forecast the quality problems happened in forming process, which provides the theoretical basis for design of stamping process and mold.

Study of the Parameters of Deep Drawing Process Based on the Simulation of Dynaform

2012 ◽  
Vol 249-250 ◽  
pp. 51-58
Author(s):  
Qing Wen Qu ◽  
Tian Ke Sun ◽  
Shao Qing Wang ◽  
Hong Juan Yu ◽  
Fang Li
Keyword(s):  
Friction Coefficient ◽  
Sheet Metal ◽  
Deep Drawing ◽  
Drawing Process ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Deep Drawing Process ◽  
Drawing Die ◽  
Drawing Speed

A simulation of deep drawing process on the sheet metal was done by using Dynaform, the influence of blank holder force, deep drawing speed and friction coefficient on the forming speed of sheet metal in the deep drawing process were got. The forming speed of sheet metal determines the quality of deep drawing, in the deep drawing process the blank holder force and the deep drawing speed are controllable parameters, the friction coefficient can be intervened and controlled, and it’s a manifestation of the interaction of all parameters, the main factors which influence the friction coefficient just have blank holder force, deep drawing speed and lubrication except the material. The conclusion of this study provides the basic data for the analysis of the lubrication of mould, the study of lubricant and the prediction of the service life of deep drawing die.

Research on Stamping of Aluminum Alloy Hemispherical Components Based on Numerical Simulation and Experiments

2010 ◽  
Vol 97-101 ◽  
pp. 236-239
Author(s):  
Cheng Jun Han ◽  
Xin Bo Lin ◽  
Yan Bo Li
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Product Quality ◽  
Experimental Research ◽  
Simulation Software ◽  
Blank Holder Force ◽  
Forming Process ◽  
Blank Holder ◽  
Wrought Aluminum

Experimental research on stamping of wrought aluminum alloy has been an important issue at home and abroad. In this paper, taking stamping of aluminum alloy hemispherical components for example, the effects of blank holder force (BHF) on stamping forming process of aluminum alloy are explored by methods of experiments and numerical simulation. Through experiments, the forming laws of hemispherical components are found out. The research shows that the BHF has significant effects on the quality of stamping components and reasonable BHF can greatly improve the formability of hemispherical components. Additionally, by applying simulation software in stamping, the development circle of product and its moulds can be shortened, and product quality and its competitiveness in the market can be improved.

Correlating the Features of Topography to Friction by Sliding Experiments

2008 ◽  
Author(s):  
Anirudhan Pottirayil ◽  
Pradeep L. Menezes ◽  
Satish V. Kailas
Keyword(s):  
Sheet Metal ◽  
Coefficient Of Friction ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Work Piece ◽  
Manufacturing Processes ◽  
Experimental Procedure ◽  
The Coefficient Of Friction ◽  
Soft Metal

Friction can influence the quality of the finished product to a large extent in certain manufacturing processes. Sheet metal forming is a particular case, where the friction between the hard-die and the relatively soft work-piece can be extremely important. Under such conditions, topography of the harder surface can influence the resistance to traction at the interface. This paper discusses about the correlation between certain features of the surface topography and coefficient of friction based on experiments involving sliding of a few soft metal pins against a harder material. A brief description of the experimental procedure and the analysis are presented. A hybrid parameter which encapsulates both the amplitude features as well as the relative packing of peaks is shown to correlate well with the coefficient of friction.

Numerical simulation of the effects of the space-variant blank-holder force and geometrical variables in the deep-drawing process

2005 ◽  
Vol 40 (4) ◽  
pp. 375-384
Author(s):  
L Wang ◽  
T. C Lee
Keyword(s):  
Complex Shape ◽  
Geometrical Parameters ◽  
Blank Holder Force ◽  
Minor Strain ◽  
Forming Process ◽  
Blank Holder ◽  
Common Problems ◽  
Blank Size ◽  
Space Variant

The increase in quality requirements for the formed products makes it desirable to find an effective way of controlling the process to achieve complex shape products without defects. It has been proven by many researchers that the space-variant blank-holder force can improve the quality of forming to achieve a targeted shape product (no wrinkling, a high drawing depth, less variation in thickness, etc.). In the forming process, the most common problems, tearing and wrinkling, generally result from the strain condition. In this paper the effect on the strain path with various types of space-variant blank-holder force and other geometrical parameters, such as the fillet radius, the blank size, and the clearance between the die and the punch, were compared and analysed. The results showed that the space-variant blank-holder force and some geometrical parameters affect the strain distribution to various extents during the forming process. The parameters influence the negative minor strain much more than the maximum major strain.

Influence of the Blank Initial State on the Quality of the Small Drawn Parts

2013 ◽  
Vol 371 ◽  
pp. 710-714
Author(s):  
Elena Costache ◽  
Gheorghe Brabie ◽  
Augustin Jitaru
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Uniform Distribution ◽  
Drawing Process ◽  
Blank Holder Force ◽  
Initial State ◽  
Blank Holder ◽  
Part Quality ◽  
Negative Phenomena

An optimum blank quality presents the following several benefits on the drawn part quality: it leads to an improved quality of the parts; it prevents some negative phenomena (like: fracture, a uniform distribution of material thickness in the drawn part and reduction of the blank holder force required during the drawing process). In the present work, an analysis was performed concerning the influence of the initial state of blank (microhardness, thickness, surface roughness and topography) on the quality of micro/milli cylindrical drawn parts made from aluminium alloy sheets having the following thicknesses: 0.10 and 0.20 mm.

Research on Tribological Properties of Environment-Friendly Nano-MoS2 Water-Based Rolling Liquid

2020 ◽  
Vol 861 ◽  
pp. 349-353
Author(s):  
Yan Li ◽  
Ren Dong Liu ◽  
Lei Xia ◽  
Rong Sheng Sun ◽  
Jian Jun Zhang ◽  
...  
Keyword(s):  
Surface Quality ◽  
Laser Scanning ◽  
Surface Defects ◽  
Rolled Strip ◽  
Environment Friendly ◽  
Lubrication Performance ◽  
Water Based ◽  
The Coefficient Of Friction ◽  
Water Base

In this research, the four-ball tribometer was examined to evaluate the tribological behavior of environment-friendly nano-MoS2 water-based rolling liquid. This experimental method is used to measure the maximum non-seizure load (PB) and the coefficient of friction (μ). The newly introduced parameter ω can be combined with PB and μ to evaluate the tribological performances of the rolling liquid comprehensively. The rolling lubrication performance of nano-MoS2 water-base lubricant was investigated using a single stand 4-high reversing rolling mill. The surface morphologies and rolling textures of the samples were measured by laser scanning confocal microscope after cold rolling. The results show that when the concentration of nano-MoS2 is 0.4wt.%, the water-based rolling liquid has excellent tribological and lubricating properties. Meanwhile, compared with the surface quality of the rolled strip under other lubrication conditions, the surface quality of the cold-rolled strip using 0.4wt% nano-MoS2 rolling liquid as the lubrication condition is smooth without visible surface defects.

Improving the Quality in Deep Drawing of Rectangle Parts Using Variable Blank Holder Force

2010 ◽  
Vol 37-38 ◽  
pp. 521-524
Author(s):  
Yu Qing Shi
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Failure Modes ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Variable Blank Holder Force

Wrinkling and tearing are the main failure modes in sheet-metal forming. Wrinkle may occur at the start of a punch stroke if the blank-holder force (BHF) is too low, and tearing may occur at the end of a stroke if the BHF is too high. The BHF is important for deep-drawing because of an effective way to promote deep formability sheet metal. They can be reduced or eliminated by manipulating a suitable BHF during sheet-metal forming. This paper presented an attempt to determine the effect of variable BHF on the tearing and wrinkling and investigated using 08Al sheet metal. The experiment show that tearing and wrinkling can be eliminated and the quality of deep drawing of rectangle parts can be improved using variable BHF.

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