A Rule-Based Process Design and Finite Element Analysis of Multistage Deep Drawing of Box Shapes

2010 ◽  
Author(s):  
A. S. Wifi ◽  
R. K. Abdel-Mageid ◽  
A. H. Gomaa ◽  
M. Shazly
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Process Design ◽  
Deep Drawing ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Element Analysis ◽  
Design Algorithm ◽  
Rule Based ◽  
Thickness Variations

In this paper a computer-aided rule-based process design of multi-staged deep drawing of box shaped shells is developed. A decomposition method is adopted in the algorithm for geometry description of the part under consideration. The shell geometry, tooling dimensions and load required are determined for each stage. A finite element analysis is carried out to verify and adjust the output of this process design algorithm. The deformation severity and the resulting strains and thickness variations are investigated. The forming limit diagram (FLD) is adopted as a basic reference to monitor possible part failure in the process.

Effect of temperature and punch speed on forming limit strains of AA5182 alloy in warm forming and improvement in failure prediction in finite element analysis

2017 ◽  
Vol 52 (4) ◽  
pp. 258-273 ◽  
Author(s):  
D Raja Satish ◽  
D Ravi Kumar ◽  
Marion Merklein
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Strain Rate ◽  
Deep Drawing ◽  
Failure Prediction ◽  
Forming Limit ◽  
Element Analysis ◽  
Working Temperature ◽  
Warm Working ◽  
Punch Speed

Formability of AA5182-O aluminum alloy sheets in the warm working temperature range has been studied. Forming limit strains of sheets of two different thicknesses have been determined experimentally in different modes of deformation (biaxial tension, plane strain and tension–compression) by varying temperature and punch speed. A correlation has been established for plane strain intercept of the forming limit diagram (FLD0) with temperature, punch speed and thickness from the experimental results. This correlation has been used to plot the forming limit diagrams for failure prediction in the finite element analysis of warm deep drawing of cylindrical cups. The effect of strain and strain rate on material flow behavior has been incorporated using a strain rate–sensitive power hardening law in which the strain hardening exponent and strain rate sensitivity index have been experimentally determined. The predictions from simulations have been validated by warm deep drawing experiments. Large improvement in accuracy of failure prediction has been observed using the FLDs plotted based on the developed correlation when compared to the existing method of calculating FLD0 using only strain hardening coefficient and thickness. The results clearly indicate the importance of incorporating temperature and punch speed in failure prediction of Al alloys using FLDs in the warm working temperature range.

Research on Finite Element Simulation and Test of Two-Pass Deep Drawing Forming for Conical Parts

2013 ◽  
Vol 652-654 ◽  
pp. 1966-1970
Author(s):  
Zhi Ren Han ◽  
Ze Bing Yuan
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Deep Drawing ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Element Analysis ◽  
Element Simulation ◽  
The Finite Element Analysis ◽  
Deep Drawing Test ◽  
As Stress

This paper is focus on two-Pass Deep Drawing Forming of conical axisymmetric parts, study on the finite element simulation and test of multi-Pass deep drawing part. It carry on the finite element analysis and calculation using the ANSYS/LS-DYNA software platform, analyzing the simulation results such as stress , strain distribution and formability by post-processing LSPOST software. It was done multi-Pass deep drawing test using a set of combined type mould. Based on the multi-Pass forming test by using a set of combined type mould, comparison of simulation and test data can be obtained through the forming limit diagram. The result of simulation and test is basically the same and both reflect the formability.

Experimental Platforms and Finite Element Analysis on Hot Stamping Processes

2014 ◽  
Vol 1063 ◽  
pp. 334-338 ◽  
Author(s):  
Tzu Hao Hung ◽  
Heng Kuang Tsai ◽  
Fuh Kuo Chen ◽  
Ping Kun Lee
Keyword(s):  
Heat Transfer ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Process Design ◽  
Hot Stamping ◽  
Boron Steel ◽  
Transfer Coefficients ◽  
Element Analysis ◽  
Heat Transfer Coefficients ◽  
The Finite Element Analysis

Due to the complexity of hot stamping mechanism, including the coupling of material formability, thermal interaction and metallurgical microstructure, it makes the process design more difficult even with the aid of the finite element analysis. In the present study, the experimental platforms were developed to measure and derive the friction and heat transfer coefficients, respectively. The experiments at various elevated temperatures and contact pressures were conducted and the friction coefficients and heat transfer coefficients were obtained. A finite element model was also established with the experimental data and the material properties of the boron steel calculated from the JMatPro software. The finite element simulations for the hot stamping forming of an automotive door beam, including transportation analysis, hot forming analysis and die quenching analysis were then performed to examine the forming properties of the door beam. The validation of the finite element results by the production part confirms the efficiency and accuracy of the developed experimental platforms and the finite element analysis for the process design of hot stamping.

scholarly journals Finite element analysis of deep drawing

2019 ◽  
Vol 11 (9) ◽  
pp. 168781401987456 ◽  
Author(s):  
Dyi-Cheng Chen ◽  
Li Cheng-Yu ◽  
Yu-Yu Lai
Keyword(s):  
Finite Element Analysis ◽  
Plastic Deformation ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Deep Drawing ◽  
Drawing Ratio ◽  
Element Analysis ◽  
Forming Mechanism ◽  
Analysis Process ◽  
Plastic Flow Stress

With the advancement of technology, aiming for achieving a greater lightness and smaller size of 3C products, parts processing technology not only needs to explore the basic scientific theory of materials but also needs to discuss the process of deep drawing numerical and the plastic deformation. This study is based on the square shape of the deep drawing numerical simulation, and aluminum alloy plastic flow stress was input into the finite element method for simulation of plastic deformation in the aluminum alloy friction, mold clamping force, and frequency, as well as amplitude in the influence of forming mechanism and the drawing ratio of aluminum alloy. Finite element analysis software has the function of grid automatic rebuild, which can rebuild the broken grid in the analysis into a complete grid shape, which can avoid the divergence caused by numerical calculation in the analysis process. The greater the obtained error value, the best plastic parameters can be found.

FORMING LIMIT OF AZ31B MAGNESIUM ALLOY SHEET IN THE DEEP DRAWING WITH CROSS-SHAPED DIE

2008 ◽  
Vol 22 (31n32) ◽  
pp. 6045-6050 ◽  
Author(s):  
HEON YOUNG KIM ◽  
SUN CHUL CHOI ◽  
HYUNG JONG KIM ◽  
SEOK MOO HONG ◽  
YONG SEUNG SHIN ◽  
...  
Keyword(s):  
Finite Element ◽  
Magnesium Alloy ◽  
Deep Drawing ◽  
Temperature Deformation ◽  
Dome Height ◽  
Forming Limit ◽  
Process Conditions ◽  
Geometrical Parameters ◽  
Element Analysis ◽  
Az31b Magnesium Alloy

Magnesium alloy sheets are usually formed at temperatures between 150 and 300°C because of their poor formability at room temperature. In the present study, the formability of AZ31B magnesium alloy sheets was investigated by the analytical and experimental approaches. First, tensile tests and limit dome height tests were carried out at several temperatures between 25 and 300°C to get the mechanical properties and forming limit diagram (FLD). A FLD-based criterion considering the material temperature during deformation was used to predict the forming limit from a finite element analysis (FEA) of the cross-shaped cup deep drawing process. This criterion proved to be very useful in designing the geometrical parameters of the forming tools and determining optimal process conditions such as tool temperatures and blank shape by the comparison between finite element temperature-deformation analyses and physical try-out. The heating and cooling channels were also optimally designed through heat transfer analyses.

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