Finite Element Simulation and Experimental Study of the Effect of Cone Parameter on Thickness Distribution in Hydroforming of Conical-Cylindrical Cups

2011 ◽  
Vol 189-193 ◽  
pp. 2634-2637
Author(s):  
Abdol Hamid Gorji ◽  
M. Bakhshi ◽  
S. Nourouzi ◽  
S.J. Hosseinipour ◽  
G. Mohammad-Alinejad
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Metal Forming ◽  
Thickness Distribution ◽  
Blank Holder ◽  
Sheet Surface ◽  
Multi Stage ◽  
Element Simulation ◽  
Tip Radius ◽  
Explosive Forming

Forming conical parts is one of the complex and difficult fields in sheet metal forming processes; because of the low contact area of the sheet with the punch in the initial stages of forming, too much tension is applied to the sheet causing burst occurrence. Furthermore, since the major part of the sheet surface between the blank holder and punch tip is free, wrinkles appear on the wall of the drawn parts. Therefore, these parts are normally formed in the industry by spinning, explosive forming or multi-stage deep drawing processes. In this paper, the parameters in the process of hydroforming conical parts along with using finite element simulation and experimental procedures have been studied. The punch radiuses parameters (the punch tip radius and the radius between the conical and cylinder section and their effects on the bursting and thickness distribution were investigated.

The Effect of Bending Radius on Thickness Distribution in Hydroforming of Conical-Cylindrical Cups

2011 ◽  
Vol 284-286 ◽  
pp. 1362-1365
Author(s):  
Salman Nourouzi ◽  
Abdolhamid Gorji ◽  
Mohammad Bakhshi-Jooybari ◽  
S. Jamal Hosseinipour ◽  
Ghorban Mohammad-Alinejad
Keyword(s):  
Sheet Metal Forming ◽  
Metal Forming ◽  
Major Part ◽  
Thickness Distribution ◽  
Blank Holder ◽  
Sheet Surface ◽  
Multi Stage ◽  
Bending Radius ◽  
Tip Radius ◽  
Explosive Forming

Conical parts forming is one of the complex and difficult fields in sheet metal forming processes; because of the low contact area of the sheet with the punch in the initial stages of forming, too much tension is applied to the sheet causing bursting occurrence. Furthermore, since the major part of the sheet surface between the blank holder and punch tip is free, wrinkles appear on the wall of the drawn parts. Therefore, these parts are normally formed in the industry by spinning, explosive forming or multi-stage deep drawing processes. In this paper, the effect of punch tip radius and conical- cylindrical radius on formability and thickness distribution of the conical parts for three different punch angles were studied.

Finite Element Simulation and Experimental Study of the Effect of Cone Angle on Thickness Distribution in Hydroforming of Conical-Cylindrical Cups

2011 ◽  
Vol 284-286 ◽  
pp. 1385-1388
Author(s):  
Abdolhamid Gorji ◽  
Mohammad Bakhshi-Jooybari ◽  
Salman Nourouzi ◽  
S. Jamal Hosseinipour ◽  
G. Mohammad-Alinejad
Keyword(s):  
Sheet Metal Forming ◽  
Metal Forming ◽  
Thickness Distribution ◽  
Cone Angle ◽  
Blank Holder ◽  
Sheet Surface ◽  
Multi Stage ◽  
Element Simulation ◽  
Cylindrical Parts ◽  
Explosive Forming

Forming conical parts is one of the complex and difficult fields in sheet metal forming processes. Because of low contact area of the sheet with the punch in the initial stages of forming, too much tension is applied to the sheet causing burst occurrence. Furthermore, since the major part of the sheet surface between the blank holder and punch tip is free, wrinkles appear on the wall of the drawn parts. Therefore, these parts are normally formed in industry by spinning, explosive forming or multi-stage deep drawing processes. In this paper, the effect of punch conical angle in hydroforming of conical-cylindrical parts has been studied. It is shown that by increasing the angle the thickness reduction will be reduced.

Thickness Distribution in Conical Parts Formed by Hydroforming and Conventional Multistage Deep Drawing Processes

2011 ◽  
Vol 189-193 ◽  
pp. 2884-2887
Author(s):  
Abdolhamid Gorji ◽  
Amir Reza Yaghoubi ◽  
Mohammad Bakhshi-Jooybari ◽  
Salman Norouzi
Keyword(s):  
Deep Drawing ◽  
Metal Forming ◽  
Thickness Distribution ◽  
Pure Copper ◽  
Experimental Program ◽  
Drawing Process ◽  
Blank Holder ◽  
Sheet Surface ◽  
Two Stages ◽  
Explosive Forming

Forming conical parts is one of the difficult fields in sheet metal forming processes. Because of low contact area of the sheet with the punch in the initial stages of forming, too much tension applied to the sheet that it causes bursting. Furthermore, since the major part of the sheet surface between the blank holder and punch tip is free, wrinkles appears on the wall of the drawn parts. These parts are normally formed in industry by processes such as spinning, explosive forming or multistage deep drawing. Hydroforming deep drawing is one of the special deep drawing processes which have been introduced in order to overcome some inherent problems in the conventional deep drawing with rigid tools. In the present work, an experimental program has been carried out to form and compare the forming pure copper conical-cylindrical cups by hydroforming and conventional multistage deep drawing processes. The conical parts in conventional deep drawing process formed in two stages. The results of the study demonstrate that thickness distribution are more uniform in the parts formed by hydroforming compared to conventional multi stages deep drawing processes.

Material Flow Estimation of Deep-Drawn Product by Using Finite-Element Simulation

2011 ◽  
Vol 301-303 ◽  
pp. 452-455 ◽  
Author(s):  
Yuji Kotani ◽  
Hisaki Watari ◽  
Akihiro Watanabe
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Finite Element Simulation ◽  
Material Flow ◽  
Thickness Distribution ◽  
Sheet Thickness ◽  
Original Material ◽  
Element Simulation ◽  
Thickness Prediction ◽  
Simulation And Evaluation

The approach to total weight reduction has been a key issue for car manufacturers as they cope with more and more stringent requirements for fuel economy. In sheet metal forming, local increases in product-sheet thickness effectively contribute to reducing the total product weight. Products could be designed more efficiently if a designer could predict and control the thickness distribution of formed products. This paper describes a numerical simulation and evaluation of the material flow in local thickness increments of products formed by an ironing process. In order to clarify the mechanism of the local increase in sheet thickness, a 3-D numerical simulation of deep drawing and ironing was performed using finite-element simulation. The effects of various types of finite elements that primarily affect thickness changes in original materials and thickness prediction were investigated. It was found that the sheet-thickness distribution could be predicted if the original material was relatively thick and if an appropriate type of finite element is selected.

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