A Knowledge-Based Engineering Method to Integrate Metal Forming Process Design and Simulation

1994 ◽  
Author(s):  
Tom Robertson ◽  
Biren Prasad ◽  
Ravi Duggirala
Keyword(s):  
Process Design ◽  
Metal Forming ◽  
Computer Aided Design ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Simulation ◽  
Knowledge Based ◽  
Metal Forming Process ◽  
Knowledge Based Engineering ◽  
Integrate Design

Abstract The integration of Computer Aided Design (CAD) and Finite Element Analysis (FEA) tools is an important consideration in metal forming design. Traditionally, engineering functions such as classical analysis, FEA, CAD, etc. are performed separately. The emergence of knowledge-based engineering (KBE) tools and its language-based structure provides a basis to integrate design functions. This paper presents a KBE system which effectively integrates metal forming process design and FEA analysis by automating the pre-processing required for metal forming simulation for two dimensional problems. The method will be applicable to 3D problems as FEA technology improves.

Research on the Metal Forming Process of the Muffler Tube Using Finite Element Method

2008 ◽  
Vol 385-387 ◽  
pp. 841-844
Author(s):  
Kyu Taek Han ◽  
Yi Jiong Jin
Keyword(s):  
Finite Element ◽  
Process Design ◽  
Metal Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Punch Radius ◽  
Metal Forming Process ◽  
Fracture Theory ◽  
Simulation Results ◽  
Fourth Component

A muffler is an important part used to reduce noise and to purify exhaust gas in cars and heavy equipments. Recently there has been a growing interest in the designing and manufacturing the muffler tube due to the strict environmental regulations. The technique of perforating on the muffler tube has been largely affected by the shear clearance. And considering the concentration of the force around the punch edge, it is essential to reduced it through the punch radius. In this research, finite element analysis has been carried out to predict optimal forming conditions of the muffler tube using DEFORMTM-3D. In analysis, using one-fourth component of the punch and die, metal forming process is simulated and Cockcroft-Latham ductile fracture theory is used. According to the simulation results, when the shear clearance is 0.04mm, the punch radius is 0.05mm and the value of plate holder force is 250KN, the relation of load-stroke for punch is optimized. Also the burr is minimized and optimal shear section is obtained. The simulation results are reflected to the forming process design for the muffler tube.

The Evaluation of Ductile Fracture Criteria (DFC) of 6061-T6 Aluminum Alloy

2010 ◽  
Vol 44-47 ◽  
pp. 2837-2841 ◽  
Author(s):  
Ying Tong
Keyword(s):  
Aluminum Alloy ◽  
Ductile Fracture ◽  
Metal Forming ◽  
True Strain ◽  
Mutual Support ◽  
Fracture Criteria ◽  
Forming Process ◽  
Forming Simulation ◽  
Ductile Fracture Criteria ◽  
Metal Forming Process

As one of the principal failures, ductile fracturing restricts metal forming process. Cockcroft-Latham fracture criterion is suited for tenacity fracture in bulk metal-forming simulation. An innovative approach involving physical compression experiments, numerical simulations and mathematic computations provides mutual support to evaluate ductile damage cumulating process and ductile fracture criteria (DFC). The results show that the maximum cumulated damage decreases with strain rate rising, and the incremental ratios, that is damage sensitive rate, vary uniformly during the upsetting processes at different strain rates. The damage sensitive rate decreases rapidly, then it becomes stability in a constant 0.11 after true strain -0.85. The true strain -0.85 was assumed as the fracture strain, and the DFC of 6061-T6 aluminum alloy is almost a constant 0.2. According to DFC, the exact fracture moment and position during various forming processes will be predicted conveniently.

On Applying Kriging Approximate Optimization to Sheet Metal Forming

2011 ◽  
Vol 63-64 ◽  
pp. 3-7
Author(s):  
Yan Min Xie
Keyword(s):  
Sheet Metal ◽  
Process Parameters ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Nonlinear Function ◽  
Kriging Model ◽  
Engineering Problem ◽  
Forming Process ◽  
Element Analysis ◽  
Metal Forming Process

This paper presents a methodology to effectively determine the optimal process parameters using finite element analysis (FEA) and design of experiments (DOE) based on Metamodels. The idea is to establish an approximation function relationship between quality objectives and process parameters to alleviate the expensive computational expense in the optimization iterations for the sheet metal forming process. This paper investigated the Kriging metamodel approach. In order to prove accuracy and efficiency of Kriging method, the nonlinear function as test functions is implemented. At the same time, the practical nonlinear engineering problems such as square drawing are also optimized successfully by proposed method. The results prove Kriging model is an effective method for nonlinear engineering problem in practice.

Experimental Investigations and Automatic Numerical Optimization of a Bulk Metal Forming Process to Avoid Forging Folds

2015 ◽  
Vol 651-653 ◽  
pp. 305-310
Author(s):  
Bernd Arno Behrens ◽  
Sonda Moakhar Bouguecha ◽  
Milan Vucetic ◽  
Anas Bouguecha ◽  
Mohammad Kazhai
Keyword(s):  
Process Parameters ◽  
Process Design ◽  
Numerical Optimization ◽  
Experimental Investigations ◽  
Forming Process ◽  
Element Analysis ◽  
Complex Processes ◽  
Metal Forming Process ◽  
Fold Formation ◽  
Indispensable Tool

The detection of process failures in earlier design stages is essential for preventing high additional costs and a loss of time. Here, the finite element analysis (FEA) is an inherent part of the process design. This work represents numerical and experimental investigations, which were carried out in order to identify factors that influence the fold formation in an upsetting process of hollow parts, i.e. different forging velocities, different materials or the friction. The experimental results were compared with the numerical simulations. Based on these investigations, an automatic optimization model was created, which is the focus of this work. It allows varying and optimizing the experimentally determined process parameters, influencing the fold formation, automatically with the aim to produce a workpiece free of folds. For this purpose the commercial Software-System Forge (Transvalor) was used. The results of this work provide basic information for the development of complex processes. It can be shown that the automatic numerical optimization is an indispensable tool for the process design. It helps determining optimal process parameters individually and avoiding extensive trial and error investigations and hence a loss of time and costs.

Finite Element Analysis and Formability Test on Incremental Forming of IS:513 CR3 Steel Sheets

2015 ◽  
Vol 766-767 ◽  
pp. 1109-1115
Author(s):  
S. Chezhian Babu ◽  
V.S. Senthil Kumar
Keyword(s):  
Metal Forming ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Forming Process ◽  
Element Analysis ◽  
Steel Sheets ◽  
Automobile Body ◽  
Metal Forming Process ◽  
High Flexibility ◽  
Forming Methods

Incremental forming is a recent sheet metal forming process that has high flexibility and repeatability. Unlike conventional forming methods this process is applicable mainly in the production of prototypes or small batches of automobile body panels, headlight reflectors, etc. In this investigation IS 513 CR3 Deep Drawing quality steel sheets of thickness 0.6 mm were incrementally formed into pyramids to study their formability characteristics. Experiments were conducted under three different spindle speeds (1000, 1500 and 2000 rpm), three tool feeds (1200, 1400 and 1600 mm.min-1) and three step depths (0.4, 0.5, and 0.6 mm). Forming time, thickness distribution and formability of the final components were studied. FEA models were created using Abaqus software and validated with experimental results.

scholarly journals Experimental And Theoretical Determination Of Forming Limit Curve

2015 ◽  
Vol 60 (3) ◽  
pp. 1881-1886
Author(s):  
J. Adamus ◽  
K. Dyja ◽  
M. Motyka
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Fracture Initiation ◽  
Forming Limit ◽  
Forming Process ◽  
Element Analysis ◽  
Metal Forming Process

Abstract The paper presents a method for determining forming limit curves based on a combination of experiments with finite element analysis. In the experiment a set of 6 samples with different geometries underwent plastic deformation in stretch forming till the appearance of fracture. The heights of the stamped parts at fracture moment were measured. The sheet - metal forming process for each sample was numerically simulated using Finite Element Analysis (FEA). The values of the calculated plastic strains at the moment when the simulated cup reaches the height of the real cup at fracture initiation were marked on the FLC. FLCs for stainless steel sheets: ASM 5504, 5596 and 5599 have been determined. The resultant FLCs are then used in the numerical simulations of sheet - metal forming. A comparison between the strains in the numerically simulated drawn - parts and limit strains gives the information if the sheet - metal forming process was designed properly.

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