An Adaptive Remeshing Procedure for Modeling the Clinch Forming Process

2012 ◽  
Author(s):  
Abdallah Sahyoun ◽  
Alain Rassineux ◽  
Jean-Marc Roëlandt ◽  
Carl Labergère ◽  
Khémais Saanouni
Keyword(s):  
Applied Load ◽  
Sheet Thickness ◽  
Field Variable ◽  
Tool Geometry ◽  
Forming Process ◽  
Adaptive Remeshing ◽  
Updated Lagrangian Formulation ◽  
Updated Lagrangian ◽  
Error Indicators ◽  
Diffuse Approximation

This work presents the case of a press clinching commonly met in the industry and denoted as TOX. The mechanical strength of the assembly is highly dependent on the final geometry of the clinched joint and among the numerous parameters which govern the process (applied load, lubrication, sheet thickness, friction, mechanical behavior of materials), the tool geometry plays a major role in the evolution of the final shape of the clinched joint. One of the objectives of this work is to provide an accurate numerical evolution of the final geometry of the clinched joint by the use of an adaptive remeshing procedure including error indicators and field variable transfer built by a meshless technique denoted as Diffuse Approximation. The resolution of the updated Lagrangian formulation is based on a static explicit approach (ABAQUS). Our numerical results are validated in comparison with experimental data.

scholarly journals Approche inverse améliorée pour la minimisation du retour élastique de pièces embouties

2008 ◽  
pp. 349-372
Author(s):  
Slim Ben- Elechi ◽  
Hakim Naceur ◽  
Catherine Knopf-Lenoir ◽  
Jean-Louis Batoz
Keyword(s):  
Response Surface ◽  
Process Simulation ◽  
Deep Drawing ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Inverse Approach ◽  
Surface Method ◽  
Updated Lagrangian Formulation ◽  
Updated Lagrangian ◽  
Diffuse Approximation

This work is focused on the minimization of the elastic deformed drawn parts after tools removing. We use a Response Surface Method based on Diffuse Approximation and a specific algorithm for the optimum searching. For the deep drawing process simulation, we use the Inverse Approach with stress improvements to take into account the bending and unbending effects. Internal efforts with the final workpiece shape are used for the springback calculation, using an Updated Lagrangian Formulation. Two deep drawing benchmarks are studied to validate the proposed procedure with reference to Abaqus® and Stampack® commercial codes.

Effects of Process Parameters on the Formability of Miniature Layered Cups

2015 ◽  
Vol 661 ◽  
pp. 69-76
Author(s):  
Tsung Chia Chen ◽  
Ming Long Xu
Keyword(s):  
Flow Rule ◽  
Copper Sheet ◽  
Forming Process ◽  
Elastic Plastic ◽  
Coulomb’S Friction ◽  
Updated Lagrangian Formulation ◽  
Updated Lagrangian ◽  
Finite Deformation Theory ◽  
The Relationship ◽  
Experimental Difference

Based on materials, different punch radii (0.3, 0.35, 0.4, 0.45, and 0.5 mm), two sets of diameter-diameter ratio 1.(.167, 1.25, 1.33, 1.4167, and 1.5) and 2.(1.6, 1.45, 1.33, 1.231, and 1.143), and two sets of depth ratio 1.(1.3, 1.4, 1.5, 1.6, and 1.7) and 2.(2.14, 1.875, 1.67, 1.5, and 1.36) are used for the stamping processes to analyze the simulation and experimental difference in copper sheet-metal (C1100) miniature layered cups. Prandtl-Reuss flow rule is integrated with finite deformation theory and Updated Lagrangian Formulation (ULF) to establish the incremental elastic-plastic deformation Finite Element Method in Coulomb’s Friction Law for simulating the miniature layered cup process. Generalized rmin algorithm is utilized in the forming process for dealing with elastic-plastic behaviors and die contact. From the simulation data, the relationship among deformation history, punch load, and punch stroke, the stress-strain distribution, and the distribution of the thinnest thickness by different punch radii are acquired.

scholarly journals Effect of Tool Geometry Parameters on the Formability of a Camera Cover in the Deep Drawing Process

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3993
Author(s):  
Thanh Trung Do ◽  
Pham Son Minh ◽  
Nhan Le
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Metal Flow ◽  
Sheet Thickness ◽  
Side Wall ◽  
Tool Geometry ◽  
Drawing Process ◽  
Nose Radius ◽  
Deep Drawing Process

The formability of the drawn part in the deep drawing process depends not only on the material properties, but also on the equipment used, metal flow control and tool parameters. The most common defects can be the thickening, stretching and splitting. However, the optimization of tools including the die and punch parameters leads to a reduction of the defects and improves the quality of the products. In this paper, the formability of the camera cover by aluminum alloy A1050 in the deep drawing process was examined relating to the tool geometry parameters based on numerical and experimental analyses. The results showed that the thickness was the smallest and the stress was the highest at one of the bottom corners where the biaxial stretching was the predominant mode of deformation. The problems of the thickening at the flange area, the stretching at the side wall and the splitting at the bottom corners could be prevented when the tool parameters were optimized that related to the thickness and stress. It was clear that the optimal thickness distribution of the camera cover was obtained by the design of tools with the best values—with the die edge radius 10 times, the pocket radius on the bottom of the die 5 times, and the punch nose radius 2.5 times the sheet thickness. Additionally, the quality of the camera cover was improved with a maximum thinning of 25% experimentally, and it was within the suggested maximum allowable thickness reduction of 45% for various industrial applications after optimizing the tool geometry parameters in the deep drawing process.

Comparison between an Advanced Numerical Simulation of Sheet Incremental Forming Using Adaptive Remeshing and Experimental Results

2013 ◽  
Vol 554-557 ◽  
pp. 1375-1381 ◽  
Author(s):  
Laurence Giraud-Moreau ◽  
Abel Cherouat ◽  
Jie Zhang ◽  
Houman Borouchaki
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Sheet Metal ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Computation Time ◽  
Experimental Results ◽  
Forming Process ◽  
Adaptive Remeshing

Recently, new sheet metal forming technique, incremental forming has been introduced. It is based on using a single spherical tool, which is moved along CNC controlled tool path. During the incremental forming process, the sheet blank is fixed in sheet holder. The tool follows a certain tool path and progressively deforms the sheet. Nowadays, numerical simulations of metal forming are widely used by industry to predict the geometry of the part, stresses and strain during the forming process. Because incremental forming is a dieless process, it is perfectly suited for prototyping and small volume production [1, 2]. On the other hand, this process is very slow and therefore it can only be used when a slow series production is required. As the sheet incremental forming process is an emerging process which has a high industrial interest, scientific efforts are required in order to optimize the process and to increase the knowledge of this process through experimental studies and the development of accurate simulation models. In this paper, a comparison between numerical simulation and experimental results is realized in order to assess the suitability of the numerical model. The experimental investigation is realized using a three-axis CNC milling machine. The forming tool consists in a cylindrical rotating punch with a hemispherical head. A subroutine has been developed to describe the tool path from CAM procedure. A numerical model has been developed to simulate the sheet incremental forming process. The finite element code Abaqus explicit has been used. The simulation of the incremental forming process stays a complex task and the computation time is often prohibitive for many reasons. During this simulation, the blank is deformed by a sequence of small increments that requires many numerical increments to be performed. Moreover, the size of the tool diameter is generally very small compared to the size of the metal sheet and thus the contact zone between the tool and the sheet is limited. As the tool deforms almost every part of the sheet, small elements are required everywhere in the sheet resulting in a very high computation time. In this paper, an adaptive remeshing method has been used to simulate the incremental forming process. This strategy, based on adaptive refinement and coarsening procedures avoids having an initially fine mesh, resulting in an enormous computing time. Experiments have been carried out using aluminum alloy sheets. The final geometrical shape and the thickness profile have been measured and compared with the numerical results. These measurements have allowed validating the proposed numerical model. References [1] M. Yamashita, M. Grotoh, S.-Y. Atsumi, Numerical simulation of incremental forming of sheet metal, J. Processing Technology, No. 199 (2008), p. 163 172. [2] C. Henrard, A.M. Hbraken, A. Szekeres, J.R. Duflou, S. He, P. Van Houtte, Comparison of FEM Simulations for the Incremental Forming Process, Advanced Materials Research, 6-8 (2005), p. 533-542.

Dieless Water Jet Incremental Micro-Forming

2018 ◽  
Author(s):  
Yi Shi ◽  
Jian Cao ◽  
Kornel F. Ehmann
Keyword(s):  
Process Parameters ◽  
Thin Shell ◽  
High Speed ◽  
Single Point ◽  
Sheet Thickness ◽  
Water Jet ◽  
Micro Forming ◽  
Forming Process ◽  
Thin Foils ◽  
High Pressure Water Jet

Compared to the conventional single-point incremental forming (SPIF) processes, water jet incremental micro-forming (WJIMF) utilizes a high-speed and high-pressure water jet as a tool instead of a rigid round-tipped tool to fabricate thin shell micro objects. Thin foils were incrementally formed with micro-scale water jets on a specially designed testbed. In this paper, the effects on the water jet incremental micro-forming process with respect to several key process parameters, including water jet pressure, relative water jet diameter, sheet thickness, and feed rate, were experimentally studied using stainless steel foils. Experimental results indicate that feature geometry, especially depth, can be controlled by adjusting the processes parameters. The presented results and conclusions provide a foundation for future modeling work and the selection of process parameters to achieve high quality thin shell micro products.

BENDING BEHAVIOR OF SIMPLY SUPPOTED METALLIC SANDWICH PLATES WITH DIMPLED CORES

2008 ◽  
Vol 22 (31n32) ◽  
pp. 6179-6184 ◽  
Author(s):  
DAE-YONG SEONG ◽  
CHANG GYUN JUNG ◽  
DONG-YOL YANG ◽  
DONG GYU AHN
Keyword(s):  
High Precision ◽  
Sandwich Plate ◽  
Sheet Thickness ◽  
Radius Of Curvature ◽  
Sandwich Plates ◽  
Collapse Load ◽  
Forming Process ◽  
Simply Supported ◽  
Bending Behavior ◽  
Sandwich Core

Metallic sandwich plates are lightweight structural materials with load-bearing and multi-functional characteristics. Previous analytic studies have shown that the bendability of these plates increases as the thickness decreases. Due to difficulty in the manufacture of thin sandwich plates, dimpled cores (structures called egg-box cores) are employed as a sandwich core. High-precision dimpled cores are easily fabricated in a sectional forming process. The cores are then bonded with skin sheets by multi-point resistance welding. The bending characteristics of simply supported plates were observed by the defining measure, including the radius ratio of the small dimple, the thickness of a sandwich plate, and the pattern angle (0°/90°, 45°). Experimental results revealed that sandwich plates with a thickness of 2.2 mm and a pattern angle of 0°/90° showed good bendability as the punch stroke under a collapse load was longer than other cases. In addition, the gap between attachment points was found to be an important parameter for the improvement of the bendability. Finally, sandwich plates with dimpled cores were bent with a radius of curvature of 330 mm for the sheet thickness of 2.2 mm using an incremental bending apparatus.

scholarly journals Investigation of a partial, inductive short-time heat treatment of thin metal sheets integrated into the forming process

2018 ◽  
Vol 190 ◽  
pp. 12008
Author(s):  
Benjamin Clausius ◽  
Petra Maier
Keyword(s):  
Heat Treatment ◽  
Strain Hardening ◽  
Sheet Thickness ◽  
Local Strain ◽  
Single Step ◽  
Thin Metal ◽  
Recrystallization Annealing ◽  
Forming Process ◽  
Metal Sheets ◽  
Short Time

Flanging is a widespread method in the sheet metal working industry to connect same or different materials by forming. Especially the sealing technology makes high demands on the flanging process: a low sheet thickness of the inner eyelet is necessary for proper sealing. The outer edges of the neck rings are mostly manufactured by shear cutting. The quality of the cut surface and the level of the local strain hardening influence decisively the limit of the flanging process by possible cracking. This paper is focused on the dependencies of these factors regarding thin metal sheets of different materials with a thickness down to 100 μm. It could be shown that strain hardening has a stronger effect on the process limits compared to the notch effect of the sheet edges when using standard values for the clearance of the shear cutting tool. Furthermore, a process is investigated with a partial inductive short-time heat treatment of the most deformed edge area. Due to the low thickness of the material and low heat capacities related thereto, it is possible to integrate a recrystallization annealing as single step into the forming process. As a result, the strain hardening can be removed from the affected zone directly between two forming steps to increase the process limits.

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