Simulation of Automotive Galvanized Steel Stamped Parts: Experimental and Numerical Approach

2014 ◽  
Vol 606 ◽  
pp. 125-129
Author(s):  
Azman Senin ◽  
Zulkifli Mohd Nopiah ◽  
Muhammad Jamhuri Jamaludin ◽  
Mohd Azmir Abidin ◽  
Muhamad Azuan Zaudin ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Sheet Metal ◽  
Flow Curve ◽  
Rolling Direction ◽  
Fem Analysis ◽  
Numerical Approach ◽  
Simulation Software ◽  
Galvanized Steel ◽  
Test Machine ◽  
Standard Material

In the rapid new automobile development, the use of simulation technology is highly demanded due to shorter time to market and fashionable product styling that go beyond the rule-of-thumb in the manufacturing technology. In stamping simulation, the expected predictions rest with the part formability, spring back, blank optimization, and other vehicle integration works. These predictions are conducted concurrently during detailed product design, and intensive product validation is performed based on such predictions. In current work, it has established the experimental mechanical properties and flow curve data for thin galvanized sheet metal. Furthermore, the true prediction of part formability is investigated with established data and standard material database embedded in commercial simulation software. The tensile experiments were carried out on a uniaxial hydraulic tensile test machine with sheet metal specimen and in accordance to ASTM requirements. Three different sheet metal specimens were prepared from the longitudinal, transverse and 450degrees from the rolling direction. From experimental works and formulation, the mechanical properties, anisotropy and flow curve had been obtained. Further improvement in the embedded material database increases the prediction accuracy of FEM analysis for Body-in-White structure and crash performance.

scholarly journals A Novel Damage Model to Predict Ductile Fracture Behavior for Anisotropic Sheet Metal

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 595 ◽  
Author(s):  
Hua Zhang ◽  
Hong Zhang ◽  
Fuguo Li ◽  
Jun Cao
Keyword(s):  
Sheet Metal ◽  
Fracture Behavior ◽  
Damage Model ◽  
Rolling Direction ◽  
Stress Triaxiality ◽  
Fem Analysis ◽  
Local Strain ◽  
Numerical Approach ◽  
Predominant Role ◽  
The Difference

The purpose of the present work is to investigate the fracture behavior of anisotropic sheet metal under various stress states. Notched tension and flat-grooved tension tests at 0°, 45°, and 90° directions with respect to rolling direction were carried out by a hybrid experimental–numerical approach, and then a novel damage model was proposed by coupling Hill48’s criterion. Based on this, finite element method (FEM) analysis models were established. The force–displacement responses of experiments and simulations are in good agreement, which verify the FEM models. The predictability of the damage model established for the fracture behavior of anisotropic materials was studied by comparing the fracture displacements between experiments and simulations. It is found that the predictability of novel damage model is basically consistent with predictive results. The difference of damage locations and local strain evolutions at a 45° direction is greater than the other directions. In addition, stress triaxiality does not play a predominant role in the fracture process for notched tension specimens, while it does play a predominant role for flat-grooved tension specimens.

Finite Element Analysis of Effect of Planar Anisotropy on Springback in Plane Strain Bending

2003 ◽  
Author(s):  
D. V. Raju ◽  
D. Ravi Kumar
Keyword(s):  
Finite Element ◽  
Plane Strain ◽  
Sheet Metal ◽  
Rolling Direction ◽  
Fem Analysis ◽  
Planar Anisotropy ◽  
Element Analysis ◽  
Tension Tests ◽  
Sheet Bending ◽  
Comparison Of The Results

In this paper, springback has been determined experimentally in plane strain sheet bending for a sheet with high planar anisotropy at different orientations to the rolling direction. Springback was predicted by analysis of plane strain bending using the Finite Element Method (FEM). The mechanical properties of sheet metal (at different angles to rolling direction) and anisotropic parameters were determined from uniaxial tension tests and were used as the input for FEM analysis. Analytical calculations were also carried out to predict springback at different orientations. Comparison of the results showed that FEM predictions are closer to experimental results than the analytical calculations. The present work is expected to provide more insight into understanding of the effect of anisotropy on springback in sheet bending operations and provide information which can be useful for manufacturers of sheet metal components (involving bending) to choose the optimum orientation of bend axis so as to get the desired quality after forming.

scholarly journals Impact Of Strain Rate On Mechanical Properties Of Metallic Sheets At Various Temperatures

2021 ◽  
Vol 12 (11) ◽  
pp. 1873-1879
Author(s):  
Dr BVS Rao, Et. al.
Keyword(s):  
Mechanical Properties ◽  
Strain Rate ◽  
Sheet Metal ◽  
Flow Curve ◽  
Material Flow ◽  
Room Temperature ◽  
Elevated Temperatures ◽  
Hot Forming ◽  
Strain Rates

It is known that in warm and hot forming processes, the forming speed and with-it combined strain rate has immense role on material flow in bulk and sheet metal operations. In contrast, the influence of the strain rate on the flow curve has been rarely analysed at room temperature. This work analyses the influence of strain rate on flow curve of bimetallic sheets, Copper and Aluminium metals. Evaluation of the flow curve is carried out as a function of strain rate. In this work three different strain rates are considered for three different materials viz bimetallic sheets(Cu-Al), Copper and Aluminium. In addition to this ,the evaluation of flow curve at elevated temperatures is carried out. The  Variation of mechanical properties with  strain rate are plotted and  analysed.

Residual Mechanical Parameters of Masonry Exposed to Fire: A New Numerical Approach

2015 ◽  
Vol 1119 ◽  
pp. 700-705
Author(s):  
Salvatore Russo ◽  
Francesca Sciarretta
Keyword(s):  
Mechanical Properties ◽  
Compressive Strength ◽  
Fem Analysis ◽  
Numerical Approach ◽  
Masonry Walls ◽  
Mechanical Parameters ◽  
Compressive Failure ◽  
Fire Resistance Test ◽  
Numerical Tools ◽  
The Relationship

The paper is part of a research that aims at investigating the relationship between fire and post-fire (i.e. residual) mechanical behaviour of masonry walls, paying attention to the possible exploitation of numerical tools for simplified approaches. The goal is to establish relationships between exposure severity under ISO834 conditions and decay in mechanical properties after exposure; the parameter of wall thickness is especially investigated, by choosing four different values (i.e. 12, 25, 38 and 51 cm). This is performed by means of FEM analysis with DIANA 9.4.4 software, simulating a standard ISO 834 fire resistance test followed by a mechanical compressive failure test on each investigated type of wall. The FE analyses’ outcomes allow to draw exponential expressions of the decay in compressive strength as a function of the exposure severity.

scholarly journals Directionally-Dependent Mechanical Properties of Ti6Al4V Manufactured by Electron Beam Melting (EBM) and Selective Laser Melting (SLM)

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3603
Author(s):  
Tim Pasang ◽  
Benny Tavlovich ◽  
Omry Yannay ◽  
Ben Jakson ◽  
Mike Fry ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Tensile Strength ◽  
Electron Beam ◽  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Electron Beam Melting ◽  
Rolling Direction ◽  
Laser Melting ◽  
Plate Rolling

An investigation of mechanical properties of Ti6Al4V produced by additive manufacturing (AM) in the as-printed condition have been conducted and compared with wrought alloys. The AM samples were built by Selective Laser Melting (SLM) and Electron Beam Melting (EBM) in 0°, 45° and 90°—relative to horizontal direction. Similarly, the wrought samples were also cut and tested in the same directions relative to the plate rolling direction. The microstructures of the samples were significantly different on all samples. α′ martensite was observed on the SLM, acicular α on EBM and combination of both on the wrought alloy. EBM samples had higher surface roughness (Ra) compared with both SLM and wrought alloy. SLM samples were comparatively harder than wrought alloy and EBM. Tensile strength of the wrought alloy was higher in all directions except for 45°, where SLM samples showed higher strength than both EBM and wrought alloy on that direction. The ductility of the wrought alloy was consistently higher than both SLM and EBM indicated by clear necking feature on the wrought alloy samples. Dimples were observed on all fracture surfaces.

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.

An Error-Adaptive, Non-Rigid Registration Method for the Analysis of Springback in Sheet Metal Forming

2015 ◽  
Vol 651-653 ◽  
pp. 1015-1020 ◽  
Author(s):  
Matthias Schweinoch ◽  
Alexei Sacharow ◽  
Dirk Biermann ◽  
Christoph Buchheim
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Simulation Software ◽  
Registration Method ◽  
Rigid Registration ◽  
Reference Shape ◽  
Geometric Deviations ◽  
Error Metric ◽  
Test Shape

Springback effects, as occuring in sheet metal forming processes, pose a challenge to manufacturingplanning: the as-built part may deviate from the desired shape rendering it unusable forits intended purpose. A compensation can be achieved by modifying the forming tools to counteractthe shape deviations. A prerequisite to compensation is the knowledge of correspondences (ui; vj),between points ui on the desired and vj on the actual shape. FEM-based simulation software providesmeans to both virtually predict springback and directly obtain correspondences. In case of experimentalprototyping and validation, however, finding correspondences requires solving a registrationproblem: given a test shape Q (scan points of the as-built geometry) and a reference shape R (CADdata of the desired geometry), a transformation S has to be found to fit both objects. Correspondencesbetween S(Q) and R may then be computed based on a metric.If S is restricted to Euclidean transformations, then S(Q) results in a rigid transformation, whereevery point of Q is subject to the same translation and rotation. Local geometric deviations due tospringback are not considered, often resulting in invalid correspondences. In this contribution, a nonrigidregistration method for the efficient analysis of springback is therefore presented. The test shape Q is iteratively partitioned into segments with respect to an error metric. The segments are locally registeredusing rigid registration subject to regulatory conditions. Resulting discontinuities are addressedby minimization of the deformation energy. The error metric uses information about the deviationscomputed based on the correspondences of the previous iteration, e.g. maximum errors or changes ofthe sign. This adaptive per-segment registration allows appropriate correspondences to be determinedeven under local geometric deviations.

Heat Treatment Effects on Static and Dynamic Mechanical Properties of Sintered SINT D30 Powder Metal

2013 ◽  
Vol 592-593 ◽  
pp. 643-646 ◽  
Author(s):  
Marko Šori ◽  
Tomaž Verlak ◽  
Srečko Glodež
Keyword(s):  
Mechanical Properties ◽  
Complex Geometry ◽  
Low Cost ◽  
Surface Hardness ◽  
Load Ratio ◽  
Tensile Tests ◽  
Test Machine ◽  
Strain Diagram ◽  
Powder Metal ◽  
Sintered Steel

Low cost, low material waste and good accuracy in components with complex geometry are the main reasons for powder metallurgy to be considered as a promising manufacturing process for the future. Like wrought steel, sintered steel can also be heat treated to increase surface hardness and to improve strength. This paper compares mechanical properties of the hardened sintered steel with the sintered steel of the same powder metal SINT D30. Firstly, the static strength of both samples is determined by quasi-static tensile tests. Results are compared in stress strain diagram and they show that the tensile strength of the hardened sintered steel SINT D30 can surpass 700 MPa. The main focus of this study is however fatigue behaviour of the sintered steel. Both sets of samples are tested on a pulsating test machine with the load ratio of R = 0. The first sample is subjected to a load that corresponds to 90 % of the yield strength and is then gradually lowered to achieve one million stress cycles without breakage. Obtained results are then presented as Wöhler curves and compared in S-N diagram.

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