Development of Parametric Simulation Models for Metal Forming Processes of Plate Structures

2018 ◽  
Author(s):  
Tom Wurzler ◽  
Thomas Lindemann ◽  
Josefine Kistner ◽  
Patrick Kaeding
Keyword(s):  
Metal Forming ◽  
Simulation Models ◽  
Metal Plate ◽  
The Finite Element Method ◽  
Forming Process ◽  
Common Procedure ◽  
Plate Structures ◽  
Metal Plates ◽  
Die Structure ◽  
Different Types

During the process of workpiece productions in metal forming industries, it is necessary to control the results of the reshaped piece to ensure its quality. A common procedure of metal plate forming processes is given by the application of an upper and lower die. Therefore, ribbed die configurations can be used. To simulate the forming process of metal workpieces, the Finite Element Method (FEM) is a feasible tool. In this paper, a parametric model of a ribbed die structure is developed with the specification that only small imperfections on the workpiece surfaces will appear after the forming process. The workpieces in this paper are plates with thickness values equal and greater than 20mm. Furthermore, the springback behaviour of the different workpieces will be in the main focus of the proposed analyses. The results of the simulations are used to developed different types of holder configurations instead of the lower die. This concept might further reduce the costs of forming processes of large metal plates.

Experimental Analysis of Velocity Fields in Hot Extrusion of Aluminium Alloy 6351

2011 ◽  
Vol 491 ◽  
pp. 145-150 ◽  
Author(s):  
Marcelo Martins ◽  
Sérgio Tonini Button ◽  
José Divo Bressan
Keyword(s):  
Metal Forming ◽  
Internal Flow ◽  
Hot Extrusion ◽  
Experimental Tests ◽  
Velocity Fields ◽  
The Finite Element Method ◽  
Forming Process ◽  
Complex Shapes ◽  
Metal Forming Process ◽  
Volume Method

Hot extrusion is a metal forming process with a huge importance in the manufacturing of long metallic bars with complex shapes, and because of this, academics and industries are especially interested in better understanding how metal flows during the process. In order to have a reliable computational tool that can help to solve and to obtain material internal flow, experimental tests and numerical simulation with the finite element method were carried out to obtain results of the velocity fields generated in hot direct extrusion of aluminum billets (aluminum alloy 6351). The experimental results of the velocity field will be used to validate a computational code based on the finite volume method.

Finite Element Modeling of Superplastic Sheet Metal Forming for Cavity Sensitive Materials

2003 ◽  
Vol 125 (3) ◽  
pp. 256-259 ◽  
Author(s):  
K. M. Liew ◽  
H. Tan ◽  
M. J. Tan
Keyword(s):  
Finite Element ◽  
Metal Forming ◽  
Present Model ◽  
Cavity Growth ◽  
Rate Sensitivity ◽  
Superplastic Forming ◽  
The Finite Element Method ◽  
Forming Process ◽  
Strain Limit ◽  
Microstructural Mechanism

In this paper, a constitutive equation for superplasticity, which is based on the microstructural mechanism of superplastic deformation taking into account the effects of deformation damage, is incorporated into the finite element method to simulate the superplastic forming process. The effects of strain rate sensitivity, cavity growth and imposed hydrostatic pressure on the strain limit are studied. The predicted results are validated through the comparison with the existing experimental data. It is found that the present model produces accurate results in all cases.

Numerical Simulation of Eccentric Explosive Forming Using Cylindrical Pressure Vessel

2012 ◽  
Author(s):  
Hirofumi Iyama ◽  
Shigeru Itoh
Keyword(s):  
Numerical Simulation ◽  
Shock Wave ◽  
Metal Forming ◽  
Metal Plate ◽  
Forming Process ◽  
Underwater Shock Wave ◽  
Metal Forming Process ◽  
Underwater Shock ◽  
Explosive Forming ◽  
Free Metal

Explosive forming is one of the effective metal forming methods using underwater shock wave generated by the detonation of an explosive. The experiment of eccentric spherical free metal forming by this method was carried out. This free metal forming process does not use require expensive metal die. We used simple metal die with only circular edges and considered the metal plate formed to required shape using this method. It was possible to change the pressure distribution applied on the metal plate by changing the set-up position of the explosive and the shape of the device. We have considered this method to cause lessen cost in the small production by various types of metal forming process. In this paper, we introduce the method of eccentric spherical free metal forming using underwater shock wave and present the experimental results. The numerical simulation on this method by FDM (Finite Difference Method) was carried out. In this paper, those results are discussed.

Position and the Size of Drawbeads for Sheet Metal Forming with the Finite Element Method

2014 ◽  
Vol 607 ◽  
pp. 112-117
Author(s):  
Khemajit Sena ◽  
Surasith Piyasin
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Drawing Process ◽  
The Finite Element Method ◽  
Forming Process ◽  
Deep Drawing Process ◽  
Metal Forming Process ◽  
Element Method

This study aims to find a solution to improve the formability in a deep drawing process. For this purpose drawbeads were used to avoid wrinkles and ruptures. The finite element method was applied to simulate the 3D metal forming process using a die and drawbead. The drawbead amount, position, size and form were studied for their affects on the formability. 3 drawbead patterns with 3 different heights were examined. The simulation was performed for each drawbead pattern and each drawbead geometrical parameter and the failure elements were counted. The best pattern chosen was the pattern that resulted in the least failure elements.

A Velocity Approach to Elasto-Plastic and Elasto-Viscoplastic Calculation by the Finite Element Method

1990 ◽  
Vol 112 (2) ◽  
pp. 150-154 ◽  
Author(s):  
J. L. Chenot ◽  
M. Bellet
Keyword(s):  
Finite Element ◽  
Metal Forming ◽  
Time Discretization ◽  
The Finite Element Method ◽  
Forming Process ◽  
Element Discretization ◽  
Numerical Tests ◽  
Metal Forming Process ◽  
Order Scheme ◽  
Complete Set

A second order scheme for the time discretization of the elasto-plastic or elasto-viscoplastic behavior is proposed, based on a velocity approach. The complete set of equations is given for the evolution problem in the case of small rotations approximation. The method is quite general and may be applied to a large class of constitutive equations. The finite element discretization is briefly outlined and it is shown that the procedure is quite similar to that of previous displacement formulations. A numerical example concerning the sheet metal forming process, with an elasto-viscoplastic behavior and a membrane approximation, is presented. The numerical tests show a considerable improvement in accuracy for a given increment of time.

Evaluation of Drawability of Titanium Welded Sheets / Ocena Tłocznosci Spawanych Blach Tytanowych

2013 ◽  
Vol 58 (1) ◽  
pp. 139-143 ◽  
Author(s):  
P. Lacki ◽  
J. Adamus ◽  
W. Wieckowski ◽  
J. Winowiecka
Keyword(s):  
Metal Forming ◽  
Pure Titanium ◽  
Commercially Pure Titanium ◽  
The Finite Element Method ◽  
Forming Process ◽  
Blank Holder ◽  
Design And Optimization ◽  
Commercially Pure ◽  
Titanium Grade ◽  
Hemispherical Punch

In the paper experimental and numerical results of sheet-metal forming of titanium welded blanks are presented. Commercially pure titanium Grade 2 (Gr 2) and Ti6Al4V titanium alloy (Gr 5) are tested. Forming the spherical cups from the welded Gr 2 || Gr 5 blanks, and uniform Gr 2 and Gr 5 blanks is analysed. Numerical simulations were performed using the PamStamp 2G v2012 program based on the finite element method (FEM). Additionally, drawability tests using the tool consisting of die, hemispherical punch and blank-holder were carried out. Thickness changes and plastic strain distributions in the deformed material are analysed. The obtained results show some difficulties occurring during forming of the welded blanks made of titanium sheets at the same thicknesses but at different grades. It provide important information about the process course and might be useful in design and optimization of the sheet-titanium forming process.

Effect of Shot Peen Forming with Large Balls on Fatigue Resistance of 2024-T351 Aluminum Alloy

2013 ◽  
Vol 816-817 ◽  
pp. 266-270
Author(s):  
Ming Tao Wang ◽  
Yuan Song Zeng ◽  
Jian Qin Shang ◽  
Xia Huang ◽  
Xue Piao Bai
Keyword(s):  
Aluminum Alloy ◽  
Fatigue Resistance ◽  
Shot Peening ◽  
Metal Forming ◽  
Forming Process ◽  
Surface Strengthening ◽  
Peen Forming ◽  
Different Types ◽  
Metal Forming Process ◽  
Aeronautical Industry

Shot peen forming different from shot peening is a metal forming process widely used in aeronautical industry. Different types of tension-tension fatigue specimens after peen forming were tested. The results show that the fatigue life of specimens peen formed with large balls except edges is 35.4% higher than that of unpeened specimens, while the life of the specimens with whole surface peen formed is 23.2% lower than that of the unpeened specimens. In addition, shot peening specimens which have been peen formed as a surface strengthening way can significantly improve the fatigue resistance. Moreover, when the specimen is peen formed except edges, the position of crack source is from the indentation region to subsurface.

scholarly journals Experimental and Simulation investigations of Micro Flexible Deep Drawing Using Floating Ring Technique

2018 ◽  
Vol 14 (3) ◽  
pp. 20-31
Author(s):  
Zaid H. Mahmood ◽  
Ihsan K. Irthiea ◽  
Kadum A. Abed
Keyword(s):  
Deep Drawing ◽  
Metal Forming ◽  
Simulation Models ◽  
Forming Process ◽  
Flexible Tool ◽  
Micro Deep Drawing ◽  
High Production Rate ◽  
Commercial Code ◽  
Application Potential ◽  
Set Up

Micro metal forming has an application potential in different industrial fields. Flexible tool-assisted sheet metal forming at micro scale is among the forming techniques that have increasingly attracted wide attention of researchers. This forming process is a suitable technique for producing micro components because of its inexpensive process, high quality products and relatively high production rate. This study presents a novel micro deep drawing technique through using floating ring as an assistant die with flexible pad as a main die. The floating ring designed with specified geometry is located between the process workpiece and the rubber pad. The function of the floating ring in this work is to produce SS304 micro cups with profile radius precision as required as possible. The finite element simulations are accomplished using the commercial code Abaqus/Standard. In order to verify the simulation models, micro deep drawing experiments are carried out using a special set up developed specifically to meet the requirements of the simulations. The results revealed that the proposed technique is feasible to be adopted for producing micro cups with remarkable application capability in miniaturization technology.

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