scholarly journals Modelling and Microstructural Aspects of Ultra-Thin Sheet Metal Bundle Cutting

Metals ◽  
2019 ◽  
Vol 9 (2) ◽  
pp. 162 ◽  
Author(s):  
Jarosław Kaczmarczyk ◽  
Aleksandra Kozłowska ◽  
Adam Grajcar ◽  
Sebastian Sławski
Keyword(s):  
Thin Sheet ◽  
Thin Metal ◽  
Experimental Investigations ◽  
The Finite Element Method ◽  
Metal Sheets ◽  
Fracture Area ◽  
Thin Sheet Metal ◽  
Simulation Results ◽  
Scanning Electron ◽  
Good Agreement

The results of numerical simulations of the cutting process obtained by means of the finite element method were studied in this work. The physical model of a bundle consisting of ultra-thin metal sheets was elaborated and then submitted to numerical calculations using the computer system LS-DYNA. Experimental investigations rely on observation of metallographic specimens of the surfaces being cut under a scanning electron microscope. The experimental data showing the microstructure of an ultra-thin metal bundle were the basis for the verification of the numerical results. It was found that the fracture area consists of two distinct zones. Morphological features of the brittle and ductile zones were identified. There are distinct differences between the front and back sides of the knife. The experimental investigations are in good agreement with the simulation results.

Prediction of Wrinkling Initiation and Growth in Aluminum 5456-H116, Alloy Sheets by Finite Element Analysis of Yoshida Test

2012 ◽  
Vol 197 ◽  
pp. 686-690
Author(s):  
Amer Sattar ◽  
Irfan Anjum Manarvi ◽  
Manzar Masud
Keyword(s):  
Finite Element ◽  
Yield Strength ◽  
Thin Sheet ◽  
Aviation Industry ◽  
Good Tool ◽  
Element Analysis ◽  
Metal Plates ◽  
Initiation And Propagation ◽  
Metal Sheets ◽  
Thin Sheet Metal

Wrinkling is one of the most undesirable effects during forming of thin sheet metal plates. It deforms the surfaces and either hampers further assembly or creates stress concentration regions which may fail during operations. Yoshida wrinkling test is considered as one good tool to analyse the wrinkling properties of sheet metals. Alluminium alloys are most commonly used in aviation industry where wrinkling initiation and its propagation is considered an even serious defect. Present research was therefore focussed on Finite Element simulations of Allumium Alloy-5456-H116 metal sheets specimens of the standard shape of Yoshida specimen. During simulations the applied load values were equal to Yield strength, yield strength +10%, and Yield strength -10%. Wrinkling initiation and propagation was observed as deformations along X,Y and Z axis on a predefined path of the specimen and stress values at this path were also evaluated. Findings have been established through an overview of deformation along each axis corresponding to stress values at that location on the path.

scholarly journals Modelling of Guillotine Cutting of a Cold-Rolled Steel Sheet

Materials ◽  
2019 ◽  
Vol 12 (18) ◽  
pp. 2954 ◽  
Author(s):  
Jarosław Kaczmarczyk
Keyword(s):  
Steel Sheet ◽  
Cutting Process ◽  
Experimental Investigations ◽  
Rolled Steel ◽  
The Finite Element Method ◽  
Cold Rolled Steel ◽  
Cold Rolled ◽  
Cutting Processes ◽  
Professional Tool ◽  
Good Agreement

In this paper, the modelling of a cutting process of a cold-rolled steel sheet using a symmetrical cutting tool is presented. The fast-changing nonlinear dynamic cutting process was elaborated by means of the finite element method and the computer system LS-DYNA. Experimental investigations using scanning electron microscopy were performed and the results are presented in this work. The numerical results were compared with experimental ones. The comparison shows a good agreement between the results obtained by means of numerical modelling and those received from experimental investigations. The numerical simulations of the cutting process and the experimental investigations aimed to understand the mechanism of the cutting process. They serve as a highly professional tool for carrying out research investigating the behavior of complex nonlinear fast-changing dynamical cutting processes in the future.

Comparison of Offset and Wiping Z-Die Designs for Precision Z-Bent Part Fabrication

2018 ◽  
Vol 140 (2) ◽  
Author(s):  
Sutasn Thipprakmas ◽  
Pakkawat Komolruji ◽  
Wiriyakorn Phanitwong
Keyword(s):  
Fem Simulation ◽  
The Finite Element Method ◽  
Spring Back ◽  
Bend Radius ◽  
Dimensional Precision ◽  
Bending Process ◽  
Simulation Results ◽  
Bend Angles ◽  
Selection Of ◽  
Good Agreement

In recent years, the requirements for high dimensional precision on Z-bent shaped parts have become increasingly stringent. To attain these requirements, the suitable selection of the Z-die bending type has to be considered much more strictly. In this research, two types of Z-bending processes, offset Z-die bending and wiping Z-die bending, were investigated using the finite element method (FEM) to identify the spring-back characteristics and dimensions of Z-bent shaped parts. In the case of offset Z-die bending, the spring-back characteristics on both bend angles were similar. In contrast, in the case of wiping Z-bending, the spring-back characteristics on both bend angles were different. In addition, the dimensions of the Z-bent shaped parts were investigated. It was found, in the case of wiping Z-bending, that web thinning was generated and the outer bend radius was out of tolerance. To validate the FEM simulation results, experiments were carried out. The FEM simulation results showed good agreement with the experimental results in terms of the bend angles and the overall geometry of the Z-bent shaped parts. To achieve precise Z-bent shaped parts, the suitable selection of Z-die bending type in the Z-die bending process is very important.

Vibration characteristics analysis of disordered two-span beams with numerical and experimental methods

2017 ◽  
Vol 24 (16) ◽  
pp. 3641-3657 ◽  
Author(s):  
Shenglin Zhou ◽  
Fengming Li ◽  
Chuanzeng Zhang
Keyword(s):  
Time History ◽  
Frequency Equation ◽  
Vibration Characteristics ◽  
Experimental Investigations ◽  
Superposition Method ◽  
The Finite Element Method ◽  
Response Curves ◽  
Modal Superposition Method ◽  
Characteristics Analysis ◽  
Good Agreement

Numerical and experimental investigations on the vibration behaviors of the disordered two-span beams have been conducted. The dynamics model of the two-span beam is established and solved by means of the modal superposition method. According to the boundary conditions, the frequency equation of the two-span beam is obtained, and the natural frequencies, vibration modes, frequency response curves, and time-history responses of the structure are also obtained consequently. Considering the structural size disorder due to the two different sub-span lengths of the two-span beam, a disorder ratio is introduced in terms of the two sub-span lengths and its influences on the vibration characteristics of the structure are analyzed. By comparing the results from numerical calculation with those from the finite element method (FEM) and experiments, good agreement is observed, which verifies the validity of the present investigations.

Study on Hydraulic Deep Drawing of Square Cups

2014 ◽  
Vol 626 ◽  
pp. 334-339
Author(s):  
Te Fu Huang ◽  
Hsin Yi Hsien ◽  
Yan Jia Chen
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
The Finite Element Method ◽  
Experimental Apparatus ◽  
Punch Load ◽  
Simulation Results ◽  
Good Agreement ◽  
Element Method

The friction holding effect and the friction reducing effect occurring during Hydraulic Deep Drawing and the pre-bulging resulting in more plastic deformation on products are applied on sheet hydro-forming. For Hydraulic Deep Drawing of a square cup, the thickness distribution and the relation between the height and the pressure of pre-bulging are simulated with SPCC steels as the specimen by the finite element method. An experimental apparatus of sheet hydro-forming has been constructed to carry out the hydraulic deep drawing experiments of square cups. Experimental thickness distribution and punch load are compared with simulation results. Good agreement was found. The flow patterns of the circular and square blanks with the condition of being firmly pressed against the punch observed from the experiments are in agreement with the predicted results.Keywords:Hydraulic Deep Drawing, sheet hydro-forming, finite element method

Effects of different cooling conditions on friction stir processing of A356 alloy: Numerical modeling and experiment

2021 ◽  
pp. 095440622110456
Author(s):  
Mostafa Akbari ◽  
Parviz Asadi
Keyword(s):  
Wear Resistance ◽  
Temperature Distribution ◽  
Simulation Model ◽  
Material Flow ◽  
A356 Alloy ◽  
Experimental Investigations ◽  
Air Cooling ◽  
The Finite Element Method ◽  
Friction Stir ◽  
Good Agreement

In the present work, the effects of in-process cooling are investigated on the material flow, temperature distribution, axial force, wear resistance, and microstructural and mechanical properties of friction stir processed (FSPed) Al-Si aluminum alloy. The finite element method (FEM) was developed for modeling the process, based on the eulerian-lagrangian technique, and then verified by the experimental force and temperature histories. Next, the material flow and temperature distribution during the friction stir process (FSP) with in-process cooling under different conditions were considered. After that, the experimental investigations, including the optical microscopy, hardness, and wear tests, were conducted. Finally, the stir zone (SZ) shape obtained by experiments and simulation model were compared for the FSPed samples without cooling and with air cooling. The material flow achievements reveal that using a coolant affects the material flow in the pin-driven zone more significantly than in the shoulder-driven zone, leading the SZ to change from the basin shape into the V shape. The SZ shapes obtained from the experiments and the simulation model show a good agreement between the shapes of the samples FSPed without cooling and with air cooling. Moreover, experimental results showed that using in-process cooling reduces Si particles' size and thus significantly increases the hardness and wear resistance. The Si particles size is reduced from 10 μm in the base metal to 2.6 μm and 2 μm in the air-cooled and water-cooled samples. Consequently, the wear mass loss reduced almost 28% and 40%, and hardness increased almost 35% and 80% for the air-cooled and water-cooled samples compared to the processed samples without coolant.

Numerical Simulation of Cold Press Forging Forming for Stepped Hole of Thin Sheet Metal

2011 ◽  
Vol 121-126 ◽  
pp. 249-253
Author(s):  
Ke Sheng Wang ◽  
Jian Lin Liu ◽  
Xiao Wei Chen
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Thin Sheet ◽  
Effective Strain ◽  
Optimum Process ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Thin Sheet Metal ◽  
Deform 3D ◽  
Good Agreement

An optimum process for a two-step press forging of stepped holes in a metal sheet was proposed .Numerical simulation on the two-step process was carried out by using DEFORM-3D. Distributions of effective strain and effective stress were obtained. The study showed that the process not only can form the stepped, but also can increase the surface quality and strength of stepped holes in sheet metal parts, According to the numerical simulation’s process parameter , an experimental die was designed, the simulation results were in good agreement with the experimental data

scholarly journals Use of Electronic Modules on Device for Tribological Research in the Field of Plastic Deformation of Slim Metal Sheets

2020 ◽  
Vol 20 (2) ◽  
Author(s):  
Tomislav Vujinović ◽  
Dragan Mihić ◽  
Esad Jakupović
Keyword(s):  
Plastic Deformation ◽  
Sheet Metal ◽  
Thin Sheet ◽  
Scientific Paper ◽  
Research Process ◽  
Metal Fabrication ◽  
Research Systems ◽  
Metal Sheets ◽  
Thin Sheet Metal ◽  
Numerical Process

Electronic modules are important components of manufacturing and research equipment in the field of plastic deformation of sheet metal fabrication, as well as in other processes. Depending on the type and complexity of the production or research process, different electronic modules are also used. The indispensable electronic modules in production as well as experimental (research) systems are: encoders, signal processing, A/D and D/A converters, required software of all levels, all the way to large packages for numerical process simulation. This scientific paper presents an original computerized device for testing tribological influences in plastic deformation of slim (thin) sheet metal forming (fabrication), whose control base consists of electronic modules. Some results are also shown as dependencies, obtained by testing on this developed device.

Development of a Novel Process for Manufacturing of Fuel Cell Bipolar Plates: Internal Pressure Assisted Embossing of Micro-Channels With In-Die Mechanical Joining

2006 ◽  
Author(s):  
Sasawat Mahabunphachai ◽  
Muammer Koc¸ ◽  
Jun Ni
Keyword(s):  
Fuel Cell ◽  
Sheet Metal ◽  
Thin Sheet ◽  
Experimental Investigations ◽  
Bipolar Plates ◽  
Bond Quality ◽  
Mechanical Joining ◽  
Post Process ◽  
Micro Channels ◽  
Thin Sheet Metal

A novel process for manufacturing of fuel cell bipolar plates was developed and described in this paper. This process combines the hydroforming of double thin sheet metal blanks with in-die mechanical joining to enable integrated forming of micro-channels on both surfaces (as anode and cathode) and at the middle (as cooling channels) in a single operation, thus, reducing post process operations, variation in dimensional tolerances, and cost while promises to increase the producibility, product quality, and performance of the fuel cell by ensuring consistent contact resistance characteristics. This paper discussed two experimental investigations that were performed to characterize and evaluate the feasibility of the proposed manufacturing process. The first investigation involved hydroforming of micro-channels with the channels geometry of 0.5 mm in both width and height on thin sheets of stainless steel 304 with a thickness of 0.051 mm. The second investigation focused mainly on the mechanical joining process of thin sheet metal blanks. The effects of different process variables on the bond quality and the mechanisms of the bond formation were studied. The experimental results presented in this paper demonstrated that the proposed manufacturing technique is feasible for making of the fuel cell bipolar plates.

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