Variations of Energy Demand With Process Parameters in Cylindrical Drawing of Stainless Steel

Studies have indicated that reducing the process energy demand is as important as improving the energy conversion efficiency to make manufacturing equipment more energy efficient. However, little work has been done to understand the energy demand characteristics of the widely employed drawing process. In this paper, the energy demand of the cylindrical drawing process under a range of operating parameters was measured and analyzed. Since any energy saving efforts should not have negative effects on the product quality, the forming quality of the drawn part indicated by the maximum thinning and thickening ratios and variation of thickness was also considered. To identify the main contributors to energy demand and forming quality, two sets of experiments were designed based on the Taguchi method. The first set of experiments include three parameters (i.e., punch velocity, blank holder force, and drawn depth) at three levels, while the second set of experiments only include two factors (i.e., punch velocity and blank holder force) at three levels due to their impacts on the forming quality. Analysis of variance (ANOVA) and analysis of means (ANOM) were then used to analyze the experimental results. Finally, grey relational analysis (GRA) was used to reveal the correlation between the forming quality and the process energy. Results show that the mean thickness variation has the strongest relational grading with the process energy, which suggests that the process energy can be used as an effective indicator to predict mean thickness variation of the drawn part. The identified characteristics of the process energy and the forming quality can be used to select process parameters for reduced energy demands of drawing processes.

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Deep Drawing of Square-Shaped Sheet Metal Parts, Part 2: Experimental Study

Journal of Engineering for Industry ◽

10.1115/1.2901624 ◽

1993 ◽

Vol 115 (1) ◽

pp. 110-117 ◽

Cited By ~ 11

Author(s):

S. A. Majlessi ◽

D. Lee

Keyword(s):

Process Parameters ◽

Deep Drawing ◽

Process Conditions ◽

Drawing Process ◽

Blank Holder Force ◽

Blank Holder ◽

Metal Parts ◽

Sheet Metal Parts ◽

Punch Load ◽

Blank Size

The deep drawing process of square and rectangular shells were investigated under different process conditions, and using two different drawing quality steels. The main objective was to identify the significance of some of the process parameters on the outcome of the drawing operation. The process parameters examined were shape and size of blank, the blank-holder force and frictional condition between blank and tooling. The results of this investigation were presented in terms of punch load, through thickness and in-plane strain distributions, formations of flange wrinkles and fracture, and the largest possible blank size that can be drawn successfully. Some of these experimental results were used to verify the validity of a simplified analytical model which was described in the first part of this paper.

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EFFECTS OF MATERIAL ANISOTROPY AND PROCESS PARAMETERS ON THE EARING DURING CYLINDRICAL DEEP DRAWING PROCESS

Journal of Advanced Manufacturing Systems ◽

10.1142/s0219686708001243 ◽

2008 ◽

Vol 07 (01) ◽

pp. 131-135

Author(s):

TUNG-SHENG YANG ◽

RUEY-FANG SHYU

Keyword(s):

Strain Hardening ◽

Process Parameters ◽

Deep Drawing ◽

Strain Hardening Exponent ◽

Drawing Process ◽

Material Anisotropy ◽

Blank Holder Force ◽

Blank Holder ◽

Deep Drawing Process ◽

Anisotropic Property

Deep drawing process is very useful in industrial field because of its efficiency. The earing of deep drawing process is affected by many material and process parameters, such as the strain-hardening exponent, anisotropic property of blank, blank holder force, the profile radius of die, etc. In this paper, the material anisotropy and process parameters effect on the earing are investigated.

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Effect of Process Parameters on Damage during the Warm Drawing of Magnesium Alloy Shell for Notebook PC

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.339.487 ◽

2011 ◽

Vol 339 ◽

pp. 487-490

Author(s):

Ying Tong

Keyword(s):

Magnesium Alloy ◽

Low Temperature ◽

Process Parameters ◽

Alloy Sheet ◽

Drawing Process ◽

Optimal Parameters ◽

Damage Factor ◽

Blank Holder Force ◽

Blank Holder ◽

Damage Criteria

The warm drawing process from magnesium alloy sheet to notebook PC shell reveals specialities due to the low plasticity under low temperature of magnesium alloy. As Cockroft-Lathem ductile damage criteria has been introduced, the damage factors and their distribution were calculated by a series of simulations for the warm drawing process. Then the effect of a series of forming parameters on the maximum damage factor was analyzed and the crack regions were identified as the piece corners. Based on the objective of minimizing the damage factor a set of optimal parameters were achieved: temperature 250 °C, press speed 4mm/s, friction factor 0.09, concave die fillet radius 5.1mm, blank holder force 0.7 MPa, clearance between punch and die 1.15 mm.

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Dynamically Regulate and Control Complicated Auto Panel Uniform Forming

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.239-242.1543 ◽

2011 ◽

Vol 239-242 ◽

pp. 1543-1551

Author(s):

Mao Yu Zhao ◽

Qian Wang Chen ◽

Ke Min Xue ◽

Ping Li

Keyword(s):

Process Parameters ◽

Orthogonal Experiment ◽

Grey Theory ◽

Blank Holder Force ◽

Dynamic Regulation ◽

Blank Holder ◽

Forming Quality ◽

Finite Element Software ◽

Forming Defects ◽

Auto Panel

A complicated auto panel forming is nonuniform plastic course and it is critical for dynamic reasonable the process parameters to avoid and decrease non-crackle, non-wrinkle, thickness uniformity forming defects. So, the forming of auto panel right beam is simulated by finite element software while the blank holder force and depth, die radius, punch radius of draw bead are independent variables, acquiring forming quality object (the data about the crack, winkle and the thinning)by orthogonal experiment. And the weight of multi-object is calculated by analytic hierarchy process, the grey relational generating and the grey rational grade of multi-objective are all calculated by the grey theory system while forming course is subdivision.Then, the dynamic optimization process parameters of blank holder force and draw bead restrain force are attained. Furthermore, employing the dynamic regulation-control optimization data to numerically simulate the auto panel forming. The conclusion demonstrates that the forming quality is obviously increased by the optimized process parameters.

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Blank holder force optimisation strategy in deep drawing process

International Journal of Computational Materials Science and Surface Engineering ◽

10.1504/ijcmsse.2007.014873 ◽

2007 ◽

Vol 1 (2) ◽

pp. 226 ◽

Cited By ~ 2

Author(s):

Hossam H. Gharib ◽

Abdalla S. Wifi ◽

Maher Y.A. Younan ◽

Ashraf O. Nassef

Keyword(s):

Deep Drawing ◽

Drawing Process ◽

Blank Holder Force ◽

Blank Holder ◽

Deep Drawing Process

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Numerical Simulation Research on Springback Controlling Methods of Aluminum Alloy Panel during Hydroforming

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.851.163 ◽

2016 ◽

Vol 851 ◽

pp. 163-167

Author(s):

Dong Yan Lin ◽

Yi Li

Keyword(s):

Numerical Simulation ◽

Aluminum Alloy ◽

Process Parameters ◽

Orthogonal Experiment ◽

Blank Holder Force ◽

Scoring Method ◽

Simulation Research ◽

Blank Holder ◽

Hydroforming Process

The hydroforming process of the aluminum alloy panel was simulated by the software DYNAFORM. The effects of process parameters (blank holder force, depth of panel and height of draw bead) on springback of the aluminum alloy were investigated. The max springback of the panel was analyzed by weighted scoring method. Then the process parameters were synthetically optimized for the max positive and negative springback. The results showed that the height of draw bead affects obviously the comprehensive springback of the panel. The optimization of the process parameters obtained by the orthogonal experiment can effectively reduce the max springback of the panel.

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

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.249-250.51 ◽

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.

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Optimization of Process Parameters of U-Shape Sheet Metal Based on Compensation of Geometric Springback Value

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.455-456.1122 ◽

2012 ◽

Vol 455-456 ◽

pp. 1122-1127

Author(s):

Xiang Wu Jia ◽

Shu Gen Hu

Keyword(s):

Sheet Metal ◽

Process Parameters ◽

New Method ◽

Blank Holder Force ◽

Technological Parameters ◽

Blank Holder ◽

Optimization Of Process Parameters

Taking example for U-shape sheet metal, the paper studies the forming and springback process with Dynaform, how much the springback influenced by several factors is studied, including die figure, stamping velocity, the stroke, the blank holder force and friction. Then a useful conclusion can be reached: Using die figure to optimize the technological parameters remarkably reduce the springback value, it provides a new method to control and solve the springback issue.

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

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.383-390.2785 ◽

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.

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