The Influnce of Some Parameters on the Quality of Deep Drawing of Cylindrical Cups without a Blank Holder

2015 ◽  
Vol 809-810 ◽  
pp. 259-264
Author(s):  
Dan Chiorescu ◽  
Gheorghe Nagîț ◽  
Oana Dodun
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Signal To Noise Ratio ◽  
Fractional Factorial ◽  
Major Influence ◽  
Forming Process ◽  
Sheet Metal Parts ◽  
Product Surface ◽  
Experimental Trials

Deep drawing is one of the most important processes for forming sheet metal parts. Besides its importance as a forming process, cup drawing also serves as a basic test for the sheet metal formability. This article investigates the influence of the die punch clearance, the average velocity in the active stage and the lubrication on the deep drawing quality expressed by the thickness evenness on the finished product surface. In order to minimize the number of experimental trials, a fractional factorial design was developed together with an orthogonal array, thus analyzing the contribution of the three parameters under study to the quality of the deep drawing process. Using TAGUCHI’s signal-to-noise ratio, we determine that ram velocity has a major influence, followed by the clearance between the active elements, while the contribution of lubrication is negligible. The results of the research are useful in developing a sensible design of experiments.

Comparison of some Final Part Geometrical Characteristics of Cylindrical Cups Manufactured by Deep-Drawing and Two-Point Incremental Sheet Forming

2009 ◽  
Vol 410-411 ◽  
pp. 355-363 ◽  
Author(s):  
Babak Taleb Araghi ◽  
Markus Bambach ◽  
Gerhard Hirt
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Surface Strain ◽  
Forming Process ◽  
Sheet Metal Parts ◽  
Part Surface ◽  
Metal Forming Process

Asymmetric incremental sheet forming (AISF) is a new sheet metal forming process in which sheet metal parts are produced by CNC-controlled movements of a simple ball-headed forming tool. Despite its flexibility and successful application in many cases, AISF has not yet been established in an industrial context due to some still existing process limits such as severe thinning, which strongly depends on the inclination of the part surface, as well as a limited geometric accuracy due to springback. Furthermore, there is little knowledge available about the properties of parts produced by AISF, especially in comparison to deep-drawn parts. The aim of the present paper is to compare cylindrical cups manufactured by deep-drawing and AISF regarding the resulting strain and thickness distribution. For AISF, different forming strategies were applied. Comparisons of the wall thickness and surface strain distributions show similar results for the cup produced by deep-drawing and the best cup produced by AISF, but the surface strains and the sheet thinning in the parts formed by AISF were larger than in the deep-drawn part.

Comparison between Deep-Drawing and Incremental Forming Processes from an Environmental Point of View

2019 ◽  
Vol 957 ◽  
pp. 120-129
Author(s):  
Melania Tera ◽  
Cristina Maria Biris
Keyword(s):  
Comparative Study ◽  
Sheet Metal ◽  
Deep Drawing ◽  
Incremental Forming ◽  
Point Of View ◽  
Forming Process ◽  
Minimal Impact ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
The Comparative Study

Deep-drawing is an industrial forming process which allows the user to process large batches of sheet metals parts. One of the major drawbacks of this process is the complexity and the high cost of dies. In comparison incremental forming is a flexible process, allowing the user to obtain sheet metal parts without the need of using a die. The present paper aims to present a comparative study of the two forming processes by presenting the main advantages and drawbacks of each one. The comparative study, aimed on the industrial implementation of the incremental forming process requires a comparison of the two processes regarding the environmental impact. Thus, the results of the study will justify the selection of the incremental forming process in the case of small batches sheet metal parts in conditions of minimal impact on the environment.

Study of the Parameters of Deep Drawing Process Based on the Simulation of Dynaform

2012 ◽  
Vol 249-250 ◽  
pp. 51-58
Author(s):  
Qing Wen Qu ◽  
Tian Ke Sun ◽  
Shao Qing Wang ◽  
Hong Juan Yu ◽  
Fang Li
Keyword(s):  
Friction Coefficient ◽  
Sheet Metal ◽  
Deep Drawing ◽  
Drawing Process ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Deep Drawing Process ◽  
Drawing Die ◽  
Drawing Speed

A simulation of deep drawing process on the sheet metal was done by using Dynaform, the influence of blank holder force, deep drawing speed and friction coefficient on the forming speed of sheet metal in the deep drawing process were got. The forming speed of sheet metal determines the quality of deep drawing, in the deep drawing process the blank holder force and the deep drawing speed are controllable parameters, the friction coefficient can be intervened and controlled, and it’s a manifestation of the interaction of all parameters, the main factors which influence the friction coefficient just have blank holder force, deep drawing speed and lubrication except the material. The conclusion of this study provides the basic data for the analysis of the lubrication of mould, the study of lubricant and the prediction of the service life of deep drawing die.

New Criterion for Prediction of the Wrinkle Formation in Deep Drawing Process

2015 ◽  
Vol 651-653 ◽  
pp. 71-76 ◽  
Author(s):  
Mathias Liewald ◽  
Fei Han ◽  
Ranko Radonjic
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Metal Forming ◽  
Failure Modes ◽  
Limit Curve ◽  
Metal Part ◽  
Sheet Metal Parts ◽  
Forming Technology ◽  
Wrinkling Analysis ◽  
New Criterion

Wrinkling is one of the primary failure modes in deep drawing of sheet metal parts. Previous studies showed that the second principle stress can be a measure for the initiation and growth of wrinkles. The wrinkling analysis is usually made with using conical cup geometries. Recent experiments and numerical simulation results at the Institute for Metal Forming Technology (IFU) showed that the wrinkling analysis using simple conical cup geometries is not suitable for description of complex wrinkling conditions for real deep drawing processes. In the presented experimental results, fender shaped geometry was chosen as an example. During deep drawing of this geometry, different wrinkling formulation mechanisms were observed. Regarding these wrinkling mechanisms, a new wrinkling limit curve can be determined. By use of this new wrinkling limit curve, it is possible to detect the occurrence of wrinkles in each area of the formed sheet metal part until the wrinkle is finally formed.

Numerical Simulation of Forming Process for Cover with Stiffening Components Made of Grade 2 Titanium Sheet Metal

2016 ◽  
Vol 687 ◽  
pp. 206-211
Author(s):  
Wojciech Więckowski
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Empirical Studies ◽  
Strength Properties ◽  
Forming Process ◽  
Titanium Sheet ◽  
Plastic Properties ◽  
Fem Method

This study presents the findings of numerical simulations of forming process for an inspection hole cover with stiffening ribs made of thin grade 2 titanium sheet metal. The numerical simulation was carried out using the FEM method with PAMStamp 2G software. Numerical calculations were performed with consideration for the phenomenon of material strain hardening and anisotropy of plastic properties of the sheet metal formed. Properties of the grade 2 titanium alloy analysed in the simulations were adopted based on the results of the empirical studies. Adequate parameters of the forming process were selected in order to eliminate unfavourable phenomena of losing of material coherence and sheet metal wrinkling. The effect of conditions of friction between the sheet metal and tool and pressure force of the blank holder on the forming process was investigated. The analysis of the distribution of plastic strain and reduction in wall thickness of the drawn parts can be used for determination of the effect of changes in selected parameters and orientation of the specimen on the process of drawn part forming. The quality of drawn parts was assessed based on the shape inaccuracy determined during simulation of forming. The inaccuracy depended on the conditions of the process and strength properties of the titanium sheet metal.

Burr Formation in Metal Cutting Operations and some Deburring Methods

2013 ◽  
Vol 581 ◽  
pp. 235-240
Author(s):  
János Kodácsy ◽  
András Szabó
Keyword(s):  
Production Process ◽  
Sheet Metal ◽  
Metal Cutting ◽  
Burr Formation ◽  
Formation Mechanisms ◽  
Mechanical Process ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Quality Of Products

Remained burrs on edges of the parts after metal cutting operations may cause many problems in the production process and in the quality of products, therefore the burrs must be completely removed. In the paper, the authors give an outline of the elements and the technical and economical influences of the burr formation, and the characteristics of the burrs and the burr formation mechanisms. The authors present some special processes that are suitable for deburring of small pieces (e.g. Magnetic Abrasive Deburring), and a frequently applied mechanical process: power brushing. The authors have carried out many investigations regarding the magnetic abrasive deburring of small, blanked sheet metal parts, furthermore the machine deburring of large-sized metal workpieces by carbide-reinforced cylindrical brushes. The detailed conditions, data, results and conclusions of these deburring experiments are treated in the paper too.

Research on the Forming Path for Fabricating the Sheet-Metal Part with Non-Horizontal End Face Using CNC Incremental Forming

2014 ◽  
Vol 599-601 ◽  
pp. 413-416 ◽  
Author(s):  
Hu Zhu ◽  
Jin Ju ◽  
Yi Bo Liu
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Analysis Method ◽  
Metal Part ◽  
Element Analysis ◽  
Sheet Metal Parts ◽  
Cnc Incremental Forming ◽  
Forming Technology ◽  
The Finite Element Analysis

For the purpose of the fabrication of the sheet-metal parts with non-horizontal end face using the sheet metal CNC incremental forming technology, two kinds of path generating methods, namely the level path perpendicular to Z axis method and the equidistant path parallel to sheet metal are proposed in this paper. Both of the paths are generated by Visual C++ and OpenGL graphics library, the effect of the two kinds of forming paths to the forming quality of the sheet part with non-horizontal end face is researched using the finite element analysis method in this paper.

Sheet-Bulk Metal Forming of Preformed Sheet Metal Parts

2011 ◽  
Vol 473 ◽  
pp. 83-90 ◽  
Author(s):  
Thomas Schneider ◽  
Marion Merklein
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Metal Forming ◽  
Sheet Plane ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Sheet Metal Parts ◽  
Bulk Forming ◽  
Process Factors ◽  
Functional Components

Due to ecological and economic challenges there is a rising demand on closely-tolerated complex functional components. Regarding short process chains and improved mechanical properties conventional forming processes are often limited. A promising approach to meet these requirements can be seen in the combination of traditional sheet and bulk metal forming processes, to form sheet metals out of the sheet plane with typical bulk forming operations. The challenge of applying conventional bulk forming operations on sheet metal is the interaction between regions of high and low deformation, which is largely unknown in literature. To analyze this topic fundamentally, a process combination of deep drawing and upsetting is developed for manufacturing tooth-like elements at pre-drawn cups. To fully understand material flow out of the sheet plane into the tooth cavity and to identify and qualify process factors depending on the functional elements´ geometry and friction, a single upsetting stage forming a simplified model of the blank is virtually analyzed with finite-element simulation. By inhibiting the forming history of the pre-drawn blank, the upsetting process can be investigated without interactions with a previous deep drawing operation.

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