OPTIMIZATION OF INFLUENTIAL PROCESS PARAMETERS ON THE DEEP DRAWING OF ALUMINIUM 6061 SHEET USING TAGUCHI AND FINITE ELEMENT METHOD

2015 ◽  
Vol 39 (3) ◽  
pp. 605-614 ◽  
Author(s):  
Van Quang Nguyen ◽  
Balamurugan Ramamurthy ◽  
Jau-Wen Lin
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Coefficient Of Friction ◽  
Process Parameters ◽  
Deep Drawing ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Edge Radius ◽  
Plastic Deformation Behavior ◽  
Element Method

The plastic deformation behavior of axis symmetric aluminium 6061 cups was determined by analyzing the four important deep drawing process parameters, namely blank temperature, die edge radius, blank holder force and friction coefficient. Taguchi techniques along with finite element method (FEM) were used to determine the importance of process parameters. The Taguchi method was used to analyze the influence of each process parameter. From the deformation result and analysis of variance (ANOVA), it was determined that the temperature of the blank has a major influence on the deformation characteristic of aluminium 6061 sheets followed by die edge radius, coefficient of friction, and blank holder force. The optimum levels of the four factors in determining the deformed cup heights are found to be blank temperature of 450°C, die edge radius of 14 mm, coefficient of friction of 0.60 and blank holder force of 9 KN.

A FINITE ELEMENT ANALYSIS FOR THE EFFECTS OF PROCESS PARAMETERS AND MATERIAL ANISOTROPY IN THE CYLINDRICAL DEEP DRAWING

2008 ◽  
Vol 07 (01) ◽  
pp. 21-32
Author(s):  
T. S. YANG ◽  
N. C. HWANG ◽  
R. F. SHYU
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Process Parameters ◽  
Deep Drawing ◽  
Strain Hardening Exponent ◽  
Drawing Process ◽  
Material Anisotropy ◽  
Plastic Strain Ratio ◽  
Deep Drawing Process ◽  
Element Method

Deep drawing process, one of sheet metal forming methods, is very useful in industrial field because of its efficiency. The deep drawing process is affected by many material and process parameters, such as the strain-hardening exponent, plastic strain ratio, anisotropic property of blank, friction and lubrication, blank holder force, presence of drawbeads, the profile radius of die and punch, etc. In this paper, a finite element method is used to investigate the cylindrical deep drawing process. The thickness of product and the forming force predicted by current simulation are compared with the experimental data. A finite element method is also used to investigate the maximum forming load and the minimum thickness of products under various process parameter conditions, including the profile radius of die, the clearance between die cavity and punch and the blank holding force. Furthermore, the material anisotropy and process parameters effect on the earing are also investigated.

scholarly journals Prediction and optimization of thinning in automotive sealing cover using Genetic Algorithm

2015 ◽  
Vol 3 (1) ◽  
pp. 63-70 ◽  
Author(s):  
Ganesh M. Kakandikar ◽  
Vilas M. Nandedkar
Keyword(s):  
Genetic Algorithm ◽  
Finite Element Method ◽  
Finite Element ◽  
Process Parameters ◽  
Deep Drawing ◽  
Drawing Process ◽  
The Finite Element Method ◽  
Deep Drawing Process ◽  
Compressive Stresses ◽  
Element Method

Abstract Deep drawing is a forming process in which a blank of sheet metal is radially drawn into a forming die by the mechanical action of a punch and converted to required shape. Deep drawing involves complex material flow conditions and force distributions. Radial drawing stresses and tangential compressive stresses are induced in flange region due to the material retention property. These compressive stresses result in wrinkling phenomenon in flange region. Normally blank holder is applied for restricting wrinkles. Tensile stresses in radial direction initiate thinning in the wall region of cup. The thinning results into cracking or fracture. The finite element method is widely applied worldwide to simulate the deep drawing process. For real-life simulations of deep drawing process an accurate numerical model, as well as an accurate description of material behavior and contact conditions, is necessary. The finite element method is a powerful tool to predict material thinning deformations before prototypes are made. The proposed innovative methodology combines two techniques for prediction and optimization of thinning in automotive sealing cover. Taguchi design of experiments and analysis of variance has been applied to analyze the influencing process parameters on Thinning. Mathematical relations have been developed to correlate input process parameters and Thinning. Optimization problem has been formulated for thinning and Genetic Algorithm has been applied for optimization. Experimental validation of results proves the applicability of newly proposed approach. The optimized component when manufactured is observed to be safe, no thinning or fracture is observed.

Multi-Step Forward Finite Element Method for the Numerical Simulation of Sheet Metal Forming

2011 ◽  
Vol 474-476 ◽  
pp. 251-254
Author(s):  
Jian Jun Wu ◽  
Wei Liu ◽  
Yu Jing Zhao
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Mapping Method ◽  
Constitutive Relationship ◽  
Element Method

The multi-step forward finite element method is presented for the numerical simulation of multi-step sheet metal forming. The traditional constitutive relationship is modified according to the multi-step forming processes, and double spreading plane based mapping method is used to obtain the initial solutions of the intermediate configurations. To verify the multi-step forward FEM, the two-step simulation of a stepped box deep-drawing part is carried out as it is in the experiment. The comparison with the results of the incremental FEM and test shows that the multi-step forward FEM is efficient for the numerical simulation of multi-step sheet metal forming processes.

Numerical Simulation of Riveting Process

2010 ◽  
Vol 34-35 ◽  
pp. 641-645
Author(s):  
Hong Shuang Zhang
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Process Parameters ◽  
Static Method ◽  
Riveting Process ◽  
Relationship Of ◽  
The Relationship ◽  
Element Method

In order to fully understanding the distribution of residual stress after riveting and the relationship between residual stress and riveting process parameters during riveting, Finite Element Method was used to establish a riveting model. Quasi-static method to solve the convergence difficulties was adopted in riveting process. The riveting process was divided into six stages according to the stress versus time curves. The relationship of residual stress with rivet length and rivet hole clearance were established. The results show numerical simulation is effective for riveting process and can make a construction for the practical riveting.

scholarly journals Computational Fluid Dynamics (CFD) Modeling and Simulation of Flow Regulatory Mechanism in Artificial Kidney Using Finite Element Method

Membranes ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 139
Author(s):  
Tuba Yaqoob ◽  
Muhammad Ahsan ◽  
Arshad Hussain ◽  
Iftikhar Ahmad
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Diffusion Model ◽  
Process Parameters ◽  
Clearance Rate ◽  
Pore Diffusion ◽  
Large Size ◽  
Depth Analysis ◽  
Pore Diffusion Model ◽  
Element Method

There is an enormous need in the health welfare sector to manufacture inexpensive dialyzer membranes with minimum dialysis duration. In order to optimize the dialysis cost and time, an in-depth analysis of the effect of dialyzer design and process parameters on toxins (ranging from tiny to large size molecules) clearance rate is required. Mathematical analysis and enhanced computational power of computers can translate the transport phenomena occurring inside the dialyzer while minimizing the development cost. In this paper, the steady-state mass transport in blood and dialysate compartment and across the membrane is investigated with convection-diffusion equations and tortuous pore diffusion model (TPDM), respectively. The two-dimensional, axisymmetric CFD model was simulated by using a solver based on the finite element method (COMSOL Multiphysics 5.4). The effect of design and process parameters is analyzed by solving model equations for varying values of design and process parameters. It is found that by introducing tortuosity in the pore diffusion model, the clearance rate of small size molecules increases, but the clearance rate of large size molecules is reduced. When the fiber aspect ratio (db/L) varies from 900 to 2300, the clearance rate increases 37.71% of its initial value. The results also show that when the pore diameter increases from 10 nm to 20 nm, the clearance rate of urea and glucose also increases by 2.09% and 7.93%, respectively, with tolerated transport of albumin molecules.

The improvement in deep drawing process for producing air filter by using finite element method

2013 ◽  
Vol 40 (1) ◽  
pp. 125-130
Author(s):  
Trinet Yingsamphancharoen ◽  
Nakarin Srisuwan ◽  
Chira Densangarun
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Deep Drawing ◽  
Drawing Process ◽  
Air Filter ◽  
Deep Drawing Process ◽  
Element Method
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