Analysis of Draw Bead Geometry on Wall Thinning and Concave/Convex Feature in Rectangular Deep Drawn Parts

2011 ◽  
Vol 189-193 ◽  
pp. 2704-2707 ◽  
Author(s):  
Wiriyakorn Phanitwong ◽  
Sutasn Thipprakmas
Keyword(s):  
Finite Element Method ◽  
Bead Geometry ◽  
Distribution Analysis ◽  
The Finite Element Method ◽  
Bead Width ◽  
Wall Thinning ◽  
Concave Wall ◽  
Straight Wall ◽  
Convex Wall ◽  
Bead Height

The application of the draw bead could reduce the concave/convex wall features. However, it also affected the wall thinning. Therefore, it is difficult to determine the suitable draw bead geometry to obtain a straight wall without the wall thinning. In this study, the effects of draw bead geometry of height and width on concave/convex wall feature and wall thinning were investigated by using the finite element method (FEM) and experiments. Based on the stress distribution analysis, the increasing in draw bead width and the decreasing in draw bead height lead to the concave wall feature increased; however, the application of the too small draw bead width and the too large draw bead height generated the convex wall feature. The wall thinning also decreased as the draw bead width increased as well as the draw bead height decreased. Therefore, the application of suitable draw bead height and width significantly suppressed the concave/convex wall feature and wall thinning, which resulted in the straight wall with the smallest wall thinning could be achieved.

Effect of Draw Bead Height on Wall Features in Rectangular Deep-Drawing Process Using Finite Element Method

2011 ◽  
Vol 264-265 ◽  
pp. 1580-1585 ◽  
Author(s):  
Sutasn Thipprakmas
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Tensile Stress ◽  
Fem Simulation ◽  
Bead Geometry ◽  
Concave Wall ◽  
Convex Wall ◽  
Simulation Results ◽  
Bead Height ◽  
Element Method

Concave/convex wall features are usually generated in the deep-drawn parts with complicated geometry, especially the difficult-to-deep draw materials. The application of the draw bead could reduce the concave/convex wall features. However, it is difficult to determine the suitable draw bead geometry and its position to obtain a straight wall. In this study, the effects of draw bead height were investigated using the finite element method (FEM) and experiments. The application of the draw bead and the effects of its height on the concave/convex wall features could be theoretically clarified on the basis of principal stress distribution. The application of draw bead led to the decrease in tensile stress in the direction of punch movement and also increased in the tensile stress distributed to the corner zone; therefore, the concave wall feature decreased. In addition, this feature decreased as the draw bead height increased. However, the application of a very large draw bead height resulted in a convex feature. The FEM simulation results were validated by experiments in the following two cases, i.e., without and with draw bead formations. With reference to the material thickness distribution, the FEM simulation results showed a good agreement with experimental results.

Influence of coined-bead die on spring-back characteristics in V-die bending process using the finite element method

2021 ◽  
pp. 095440542199567
Author(s):  
Sutasn Thipprakmas ◽  
Arkarapon Sontamino
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Bend Angle ◽  
The Finite Element Method ◽  
Spring Back ◽  
Bead Width ◽  
Physical Experiments ◽  
Inner Radius ◽  
Bending Process ◽  
Element Method

The coined-bead technique is an effective approach for controlling the spring-back characteristics involved in sheet-metal bending. Most previous studies have focused on the application of the coined-bead punch. In this application, bead marks are commonly formed on the inner radii of the bent components. To ensure the precision of the inner bent radius, a coined-bead die can be employed. However, information and data pertaining to coined-bead die applications are currently lacking. In the present research, the influences of the coined-bead die on the spring-back characteristics during V-die bending are investigated for aluminium alloy sheets (AA1100-O), by using the finite element method (FEM) and related physical experiments. Based on material flow and stress distribution analyses, it is found that the bending mechanism of coined-bead die application (particularly in the coining stage) is different from that of coined-bead punch application. Moreover, an increase in the punch radius-to-workpiece thickness ratio and decreases in the bend angle and coined-bead width result in increased spring-back characteristics. It is revealed that the coined-bead die can be applied to prevent spring-back characteristics and the bead mark at the inner radius. However, it was also noted that the V-shape parameters should be carefully considered for coined-bead applications. In addition, it is recommended that the width of the coined-bead die should be larger than that of the coined-bead punch.

Modeling of weld bead geometry for rapid manufacturing by robotic GMAW

2015 ◽  
Vol 29 (10n11) ◽  
pp. 1540033 ◽  
Author(s):  
Tao Yang ◽  
Jun Xiong ◽  
Hui Chen ◽  
Yong Chen
Keyword(s):  
Gas Metal Arc Welding ◽  
Dimensional Accuracy ◽  
Great Accuracy ◽  
Weld Bead ◽  
Bead Geometry ◽  
Weld Bead Geometry ◽  
Bead Width ◽  
Metal Arc Welding ◽  
Bead Height ◽  
Metallic Parts

Weld-based rapid prototyping (RP) has shown great promises for fabricating 3D complex parts. During the layered deposition of forming metallic parts with robotic gas metal arc welding, the geometry of a single weld bead has an important influence on surface finish quality, layer thickness and dimensional accuracy of the deposited layer. In order to obtain accurate, predictable and controllable bead geometry, it is essential to understand the relationships between the process variables with the bead geometry (bead width, bead height and ratio of bead width to bead height). This paper highlights an experimental study carried out to develop mathematical models to predict deposited bead geometry through the quadratic general rotary unitized design. The adequacy and significance of the models were verified via the analysis of variance. Complicated cause–effect relationships between the process parameters and the bead geometry were revealed. Results show that the developed models can be applied to predict the desired bead geometry with great accuracy in layered deposition with accordance to the slicing process of RP.

scholarly journals Prediction of welding bead geometry for wire arc additive manufacturing of SS308l walls using response surface methodology

2020 ◽  
Vol 71 (4) ◽  
pp. 431-443 ◽  
Author(s):  
Le Van Thao ◽  
Mai Dinh Si ◽  
Doan Tat Khoa ◽  
Hoang Quang Huy
Keyword(s):  
Response Surface Methodology ◽  
Additive Manufacturing ◽  
Response Surface ◽  
Design Method ◽  
Welding Current ◽  
Travel Speed ◽  
Bead Geometry ◽  
Bead Width ◽  
Bead Height ◽  
Wire Arc Additive Manufacturing

In the wire arc additive manufacturing (WAAM) process, the geometry of single welding beads has significant effects on the stability process and the final quality and shape of manufactured parts. In this paper, the geometry of single welding beads of 308L stainless steel was predicted as functions of process parameters (i.e. welding current I, voltage U, and travel speed v) by using the response surface methodology (RSM). A set of experimental runs was carried out by using the Box-Behnken design method. The adequacy of the developed models was assessed by using an analysis of variance (ANOVA). The results indicate that the RSM allows the predictive models of bead width (BW) and bead height (BH) to be developed with a high accuracy: R2-values of BW and BH are 99.01% and 99.61%, respectively. The errors between the predicted and experimental values for the confirmatory experiments are also lower than 5% that again confirms the adequacy of the developed models. These developed models can efficiently be used to predict the desirable geometry of welding beads for the adaptive slicing principle in WAAM.

Affect of Part Geometry on Wall Features in Rectangular Deep-Drawing Processes Using Finite Element Method

2009 ◽  
Vol 410-411 ◽  
pp. 579-585 ◽  
Author(s):  
Sutasn Thipprakmas
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Complex Geometry ◽  
Thickness Distribution ◽  
Cost Effective ◽  
Bead Formation ◽  
Concave Wall ◽  
Convex Wall ◽  
Forming Defects ◽  
Element Method

High-quality stamped parts using cost-effective production technique are increasingly required, especially in parts with complex geometry wherein forming defects are easily generated. In this study, the concave and convex wall features were investigated for a stainless steel rectangular tray using the finite element method and related experiments. The concave and convex wall phenomena were theoretically clarified on the basis of stress distribution. The effects of tray geometry were also investigated. Increasing both the rectangle size and depth of tray, together with a decrease in the corner radius, resulted in an increase in concave wall generation. However, the effects of increasing the length or width of the rectangle affecting the concave wall were independent of each other. In addition, the application of a very large depth of tray resulted in a convex feature. The results showed that it is difficult to achieve a straight wall on both the ‘length’ and ‘width’ sides without the use of draw bead. The finite element simulation results showed a reasonable agreement with the experimental results, with reference to the material thickness distribution in both the cases of: absence of the draw bead formation; and presence of the draw-bead formation.

Simulation of tuning graphene plasmonic behaviors by ferroelectric domains for self-driven infrared photodetector applications

Nanoscale ◽  
2019 ◽  
Vol 11 (43) ◽  
pp. 20868-20875 ◽  
Author(s):  
Junxiong Guo ◽  
Yu Liu ◽  
Yuan Lin ◽  
Yu Tian ◽  
Jinxing Zhang ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Interfacial Effect ◽  
Infrared Photodetector ◽  
The Finite Element Method ◽  
Ferroelectric Domains ◽  
Element Method

We propose a graphene plasmonic infrared photodetector tuned by ferroelectric domains and investigate the interfacial effect using the finite element method.

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