Design of a Stamping Test for Investigating Surface Distortion in Sheet Metal Parts

2008 ◽  
Author(s):  
Zhengchun Fu ◽  
Ping Hu ◽  
Hui-Ping Wang ◽  
Kunmin Zhao
Keyword(s):  
Sheet Metal ◽  
Measurement Techniques ◽  
Geometric Parameters ◽  
Time Dynamic ◽  
Sheet Metal Parts ◽  
Root Cause ◽  
Class A ◽  
Surface Distortion ◽  
Metal Stamping ◽  
Surface Distortions

Surface distortions/deflections are frequently introduced into the Class “A” surfaces during sheet metal stamping processes. However, the origins of the draw die related surface distortion/deflection have not been well understood. This paper presents our design of a stamping test for the investigation of the distortion phenomenon. Five geometric parameters are first identified to represent basic geometry of typical automobile outer panel depression features around the surface distortions. Experimental stamping dies are then designed to reflect various combinations of these five geometric parameters with the assistance of numerical simulations to ensure that the designed dies are able to replicate the surface distortion phenomenon. Also, real-time dynamic measurement techniques are designed to collect historical data of strains and deflection on the stamping panels. Our preliminary tryouts show that the designed stamping test successfully replicates the distortion phenomenon observed in production stamping processes. It provides a platform for the investigation of the root-cause of the draw die related surface distortions.

Investigation and Correction of Surface Distortion in Dies With Typical Depression Features

2011 ◽  
Vol 133 (4) ◽  
Author(s):  
Hui-Ping Wang ◽  
Kunmin Zhao ◽  
Ping Hu ◽  
Zhengchun Fu ◽  
Jing-Ru Bao
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Historical Data ◽  
Time Measurement ◽  
Geometric Parameters ◽  
Class A ◽  
Real Time Measurement ◽  
Surface Distortions ◽  
Full Factorial

Surface distortions are frequently introduced into Class “A” surfaces during various sheet metal forming operations such as drawing, trimming, and flanging. The origins of these surface distortions have not been well understood. The scope of this research is to investigate the distortion that occurs in the draw operation and to find effective and practical corrective methods. Five geometric parameters are first identified to represent typical depression features in automobile outer panels. Experimental dies are then designed to reflect various combinations of these five geometric parameters with the assistance of numerical simulations to ensure that the dies can make parts free of major defects such as splits and wrinkles. Surface distortions are observed in our stamping experiments and various techniques are used to measure and record the distortions for further mathematical analysis. Historical data of strains and deflections in distortion areas are collected through real-time measurement. The effects of three geometric parameters on distortion are analyzed using a full factorial DOE model. A geometry morphing program based on UG-NX platform is developed. The program is used to morph the die face in the distortion areas. Finally, three approaches that aim to correct distortions are tried out and the die morphing proves to be a practical and effective method.

Modeling and Optimization of End Effector Layout for Handling Compliant Sheet Metal Parts

2000 ◽  
Vol 123 (3) ◽  
pp. 473-480 ◽  
Author(s):  
D. Ceglarek ◽  
H. F. Li ◽  
Y. Tang
Keyword(s):  
Sheet Metal ◽  
Material Handling ◽  
Design Stage ◽  
End Effector ◽  
Industrial Practice ◽  
Modeling And Optimization ◽  
Sheet Metal Stamping ◽  
Sheet Metal Parts ◽  
Metal Stamping ◽  
Compliant Parts

Material handling of compliant parts is one of the most critical and underresearched problems in the sheet metal stamping industry. The fundamental shortcoming of currently studied material handling systems for sheet metal stamping is the lack of analysis of its impact on part dimensional quality and production throughput. This paper addresses this problem by development of a generic methodology for modeling and optimization of part holding end-effector layout in order to minimize part dimensional deformation during handling operations. The methodology extends the design of “N-2-1” fixturing layout by adding part movability conditions. It considers part CAD model, handling direction and motion kinematic parameters to determine the best end effector layout. This methodology is realized by integrating FEM part and loading modeling with the optimization algorithm. It can be implemented into the design stage of a stamping line so that the trial and error process, which is current industrial practice, can be greatly shortened and the production throughput increased. Experimental results verify the proposed part holding end-effector layout methodology.

Modeling and Optimization of Fixture for Handling Compliant Sheet Metal Parts

1999 ◽  
Author(s):  
D. Ceglarek ◽  
H. F. Li ◽  
Y. Tang
Keyword(s):  
Sheet Metal ◽  
Material Handling ◽  
Design Stage ◽  
End Effector ◽  
Industrial Practice ◽  
Modeling And Optimization ◽  
Sheet Metal Stamping ◽  
Sheet Metal Parts ◽  
Metal Stamping ◽  
Compliant Parts

Abstract Material handling of compliant parts is one of the most critical and underresearched problems in the sheet metal stamping industry. The fundamental shortcoming of currently studied material handling systems for sheet metal stamping is the lack of analysis of its impact on part dimensional quality and production throughput. This paper addresses this problem by development of a generic methodology for modeling and optimization of part holding end-effector fixture layout in order to minimize part dimensional deformation during handling operations. The methodology extends the design of “N-2-1” fixturing layout by adding part movability conditions. It considers part CAD model, handling direction and motion kinematic parameters to determine the best end effector layout. This methodology is realized by integrating FEM part and loading modeling with the optimization algorithm. It can be implemented into the design stage of a stamping line so that the trial and error process, which is current industrial practice, can be greatly shortened and the production throughput increased. Experimental results verify the proposed part holding end-effector layout methodology.

Quantifying the Visibility of Surface Distortions in Class “A” Automotive Exterior Body Panels

2013 ◽  
Vol 135 (1) ◽  
Author(s):  
K. D. Fernholz
Keyword(s):  
Automotive Industry ◽  
Human Perception ◽  
Element Model ◽  
Subjective Assessment ◽  
Model Data ◽  
Surface Appearance ◽  
Class A ◽  
Surface Distortion ◽  
Subjective Assessments ◽  
Surface Distortions

Visible distortions in Class “A” automotive surfaces are unacceptable to vehicle customers and therefore are considered to be cosmetic defects. The automotive industry currently relies upon subjective assessment of the severity of these distortions to determine whether a component's surface appearance is acceptable. Given the inherent variability in subjective assessments, however, an objective measurement for assessing the severity of defects would be of great benefit to the industry. The issues that need to be addressed to objectively quantify the severity of one particular type of surface distortion are discussed and a methodology for quantifying the severity of that surface distortion in a way that correlates to human perception is proposed. Experimental and finite element model data supporting the proposed methodology is presented.

Automatic Tool Selection for NC Turret Operation in Sheet Metal Stamping

1994 ◽  
Vol 116 (2) ◽  
pp. 239-246 ◽  
Author(s):  
Kyung Ho Cho ◽  
Kunwoo Lee
Keyword(s):  
Sheet Metal ◽  
Shape Index ◽  
Production Performance ◽  
Tool Selection ◽  
Index Set ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Metal Fabrication ◽  
Metal Stamping ◽  
Automatic Tool

In sheet metal fabrication using an NCT (numerically controlled turret punch press) machine, automatic tool selection is a major problem to be solved to improve its production performance. However, this operation has been done either manually or semi-automatically by human experts. In this paper, we have introduced the shape-index-set to handle the shape of sheet metal parts and developed an algorithm through which one can find the successive matching curves between two curve lists, one from the punching tool and the other from the boundaries of the sheet metal part. The algorithm is used to select the tools automatically to punch out the boundaries of sheet metal parts. Several experiments are presented to prove the successful tool selection.

Experimental and Numerical Analysis of Blanking for Thin Sheet Metal Parts

2001 ◽  
Vol 4 (3-4) ◽  
pp. 319-333
Author(s):  
Vincent Lemiale ◽  
Philippe Picart ◽  
Sébastien Meunier
Keyword(s):  
Numerical Analysis ◽  
Sheet Metal ◽  
Thin Sheet ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Thin Sheet Metal

The Structure and Mechanical Properties of Aluminum Cellular Metal With Periodic Cubic Cells

2016 ◽  
Author(s):  
Xiaobing Dang ◽  
Ruxu Du ◽  
Kai He ◽  
Qiyang Zuo
Keyword(s):  
Mechanical Properties ◽  
Relative Density ◽  
Sheet Metal ◽  
Light Weight ◽  
Practical Applications ◽  
Sheet Metal Stamping ◽  
High Stiffness ◽  
The Past ◽  
Cellular Metal ◽  
Metal Stamping

As a light-weight material with high stiffness and strength, cellular metal has attracted a lot of attentions in the past two decades. In this paper, the structure and mechanical properties of aluminum cellular metal with periodic cubic cells are studied. The aluminum cellular metal is fabricated by sheet metal stamping and simple adhesion. Two sizes of specimens with cell sizes of 3mm and 5mm are fabricated. Their relative density and mechanical properties are tested by means of experiments. The results show that the cubic-cell cellular metal has high and predictable strength and hence, can be used for many practical applications.

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