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

Press Forging Forming of Stepped Holes in Thick Sheet Metal

2013 ◽  
Vol 706-708 ◽  
pp. 234-237
Author(s):  
Xu Jun Cao ◽  
Ke Sheng Wang ◽  
Yu Han ◽  
Chong Chao Lin
Keyword(s):  
Sheet Metal ◽  
Effective Strain ◽  
Extrusion Process ◽  
Thick Sheet ◽  
Element Analysis ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Thick Sheet Metal ◽  
Deform 3D ◽  
Good Agreement

Press forging forming of thick sheet metal is a combined extrusion process, which is put forward in the presently study. A new technological scheme for a two-step press forging of stepped holes in a thick metal sheet was proposed. Finite element analysis on the two-step process is 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 holes, but also can increase the surface quality and strength of stepped holes in sheet metal parts, According to the numerical simulations process parameter, an experimental die was designed, the simulation results were in good agreement with the experimental data.

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

Roll Bending of Thin Sheet Metal Parts on Press Brakes

CIRP Annals ◽  
1993 ◽  
Vol 42 (1) ◽  
pp. 295-300 ◽  
Author(s):  
E. v. Finckenstein ◽  
F. Haase ◽  
M. Kleiner ◽  
G. Reil ◽  
R. Schilling ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Thin Sheet ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Roll Bending ◽  
Thin Sheet Metal

Investigation of advanced laser-MAG tandem hybrid welding for joining gap-flawed thin sheet metal parts

2017 ◽  
Vol 62 (1) ◽  
pp. 95-104
Author(s):  
S. Egerland ◽  
H. Staufer ◽  
M. Ruehrnoessl ◽  
M. Schorn
Keyword(s):  
Sheet Metal ◽  
Thin Sheet ◽  
Hybrid Welding ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Thin Sheet Metal

Development of Inline Micro-Deburring Applying Magnetic-Field-Assisted Polishing

2010 ◽  
Vol 4 (1) ◽  
pp. 9-14 ◽  
Author(s):  
Masahiro Anzai ◽  
◽  
Takeo Nakagawa ◽  
Nobuhiro Yoshioka ◽  
Shigeki Banno ◽  
...  
Keyword(s):  
Magnetic Field ◽  
Sheet Metal ◽  
Thin Sheet ◽  
Practical Application ◽  
Metal Parts ◽  
Actual Production ◽  
Thin Sheet Metal ◽  
Actual Operation ◽  
Machine Parts ◽  
Magnetic Abrasives

The ongoing miniaturization and increasing precision of machine parts have made minute burrs generated in shearing, cutting, and grinding, a serious problem and their elimination a vital necessity. With no currently efficient way of deburring metal parts made by press-forming thin sheet metal. We applied a polishing using magnetic abrasives to micro-deburring, and used this in actual production. Results showed that three-dimensionally formed thin sheet hoops can be deburred, and clarified that nonstop operator-free deburring lines can be put into actual operation at production sites. We also attempted deburring the outer blade of an electric shaver as a practical application, attaining excellent results.

Numerical Analysis for Multi-Point Forming of Aluminum Alloy Profile

2014 ◽  
Vol 1035 ◽  
pp. 128-133 ◽  
Author(s):  
Xue Zhi Liu ◽  
Chun Guo Liu ◽  
Yuan Yao ◽  
Xue Guang Zhang
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Numerical Analysis ◽  
Sheet Metal ◽  
Cross Section ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Bending Process ◽  
A New Technique ◽  
Elastic Cushion

As a new technique to form sheet metal parts, Multi-point forming (MPF) also can be used on bending aluminum alloy profile. Since the Multi-Point Die (MPD) which replaces the traditional solid bending die is composed of many discrete punch elements, dimples always occur on the plate of profiles. To eliminate the dimpling defects, numerical simulation of the bending process with A6N01S-T5 aluminum alloy hollow profile using MPD were conducted. By comparing the bending effects on MPD with different size of punch elements and with different kind of elastic cushion, reasonable forming parameters were obtained. Pressing of Aluminum alloy profile with different radii on the MPD and solid die were simulated. The cross-section distortion indicated that the aluminum alloy profile can be formed with MPF technique while it has the advantage of flexibility. For the profile with large deformation, multi-step MPF method is a better choice due to its rapid reconfigurable characteristic.

Forming Stability Analysis of Surface Flexible Rolling

2013 ◽  
Vol 798-799 ◽  
pp. 267-271
Author(s):  
Ren Jun Li ◽  
Ming Zhe Li ◽  
Zhong Yi Cai
Keyword(s):  
Numerical Simulation ◽  
Stability Analysis ◽  
Sheet Metal ◽  
Three Dimensional ◽  
Continuous Manufacturing ◽  
Forming Process ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Flexible Rolling ◽  
Simulation Results

Surface flexible rolling method, using two integral working rolls as the forming tool, can achieve fast, flexible and continuous manufacturing of three-dimensional sheet metal parts. This paper introduces the basic principle of surface flexible rolling and discusses the numerical simulation results when the working rolls are bended as circular arcs. The stability indicates the forming effect to some extent and the flow type of the metal can be deduced from stability analysis. To integrate and analyze the simulation results by means of reverse engineering. The analysis results show that the forming process is stable and the effect of surface flexible rolling is fine. It also indicates that inhomogeneous deformation and accumulation occurs during the process. The numerical simulation and experimental results demonstrate that the surface flexible rolling is a feasible and effective way to form three-dimensional sheet metal parts.

Optimization of Superplastic Forming Processes for High Volume Production in Aeronautics

2013 ◽  
Vol 549 ◽  
pp. 189-196
Author(s):  
Andreas Nick ◽  
Joachim Zettler ◽  
Gerhard Hirt
Keyword(s):  
Sheet Metal ◽  
Thin Sheet ◽  
Superplastic Forming ◽  
High Volume ◽  
Strain Rates ◽  
Form Complex ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
High Volume Production ◽  
Volume Production

Superplastic forming (SPF) is a well-known and widely used sheet metal forming process especially useful for the production of very complex and light thin sheet metal components. The superplastic behavior of a material is highly dependent on the temperature and occurs only at a narrow range of strain rates with an optimum value that is unique for each material. Within the aeronautic industry, this process is mainly used to form complex sheet metal parts made of the titanium alloy Ti6Al4V in heat affected areas and areas where corrosion resistance plays an important role. Even though the process times of SPF are often in the range of hours and therefore recurring costs are very high, the process is sometimes still the only choice when it comes to the forming of Ti6Al4V sheet metal parts for aeronautic or aerospace applications. To overcome the problem of long process times and high costs, in recent years, a lot of research did happen with the goal of temperature reduction during forming or forming at higher strain rates. Especially the change in the aeronautic industry towards high volume production is increasing the competition between suitable forming technologies and the SPF technology can only persist if both goals, reduction of process time and recurring costs are reachable. In this paper we will address those goals and show highly useful numerical procedures to make the SPF process ready for the next generation of aerospace manufacturing.

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