Numerical Simulation and Process Optimization for Multi-Stage Forming of Wheel Centre Disc

2011 ◽  
Vol 189-193 ◽  
pp. 2770-2774
Author(s):  
Gan Wei Cai ◽  
Xi Yong Xu ◽  
Zhan Guang Zheng ◽  
Zhuan Zhang ◽  
Du Chao Wu
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Process Simulation ◽  
Metal Forming ◽  
Forming Process ◽  
Stage Number ◽  
Forming Quality ◽  
Steel Wheel ◽  
Multi Stage ◽  
Forming Characteristics

The steel wheel centre discs are usually stamped by multi-stage sheet metal forming. The stage number and the content of every stage decide if the structure-pieces can be formed successfully and the final forming quality. In this paper, the forming characteristics of wheel centre disc were analyzed firstly and the reasonable two-stage stamping scheme of drawing and inverse-drawing are adopted. The numerical simulations of multi-stage stamping process are performed and connected together through deformation transmission. By means of FLD and changes of sheet metal chickness, the formability is analyzed and the forming process is optimized. The feasibility of multi-stage forming process simulation and the validity of the optimized scheme were verified by stamping in practice.

Finite-Element Modeling of Thermal Forming of Ti-TWBs with Experimental Verification

2014 ◽  
Vol 626 ◽  
pp. 518-523
Author(s):  
C.P. Lai ◽  
Luen Chow Chan
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Experimental Verification ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Production Test ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Multi Stage ◽  
Strain Paths

The titanium tailor-welded blanks (Ti-TWBs) are being developed in different industries such as automobile and aerospace, combining the advantages of both tailor-welded blanks technology and titanium alloys. In recent decades, computer simulation of sheet metal forming processes has been employed increasingly over conventional production test and adjustment methodology to achieve the optimum and cost-effective operation procedures. Recently, certain amounts of theoretical analysis for the sheet metal forming process have been developed. However, these analyses could not be applied directly to the material under multi-stage forming process. Thus, some researchers have developed a damage-based model to predict the instability and failure of sheet metals, particularly for the above Ti-TWBs, with consideration of material damage under discontinuous or proportional loading strain paths. So far this model has been used and proved to be successful to predict formability of selected sheets of steel and aluminium alloy. However, the application of the damage-coupled model has yet to be extended to the Ti-TWBs under thermal multi-stage forming operation.The main objective of this paper is to investigate numerically the formability of Ti-TWBs under multi-stage forming process with experimental verification. Titanium alloy sheets (Ti-6Al-4V) in thickness of 0.7mm and 1.0mm were selected and laser-welded the specimen of Ti-TWBs. The model based on the damage mechanics is introduced to predict the thermal formability of Ti-TWBs with change of strain paths. In this study, the anisotropic damage model incorporate with the finite element codes and user-define material subroutine were developed to predict the formability of Ti-TWBs with change of strain paths. The mechanical properties and damage parameters of Ti-TWBs for the simulation were measured experimentally. The simulation of Ti-TWB under multi-stage forming process were then conducted and validated experimentally at similar forming conditions. The predicted results have been found to agree well with those obtained from the experiments. This analysis can be applied readily to design and manufacture TWB components or structures so as to satisfy the need of such market demands.

Reverse Engineering for Spotting of Sheet Metal Forming Parts

2010 ◽  
Author(s):  
Christine Schoene ◽  
Ralph Stelzer ◽  
Ulf Schmidt ◽  
Dietmar Suesse
Keyword(s):  
Reverse Engineering ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Process Simulation ◽  
Metal Forming ◽  
Process Engineering ◽  
Forming Process ◽  
Scientific Analysis ◽  
Measurement And Analysis ◽  
Optimisation Algorithms

The paper elucidates how to connect forming process simulation with innovative measurement- and analysis equipment thereby taking into account the machine influences. Reverse Engineering use 3D-Scanning data of sheet metal forming dies. Following this paradigm, the models simulation relies on are refined, and spotting of forming dies is subjected to a scientific analysis. That means, that with Reverse Engineering, “extended process engineering” is verified at the real spotting procedure, the comparison of simulation- and measuring results is used to evaluate how close the investigated models are to reality, extending the optimisation algorithms used for springback compensation to die spotting, the modification of the die topology will be carried out automatically thanks to new software functions.

Studies on the Processes Design of Multi-Step Sheet Metal Forming

2010 ◽  
Vol 146-147 ◽  
pp. 1855-1858
Author(s):  
Wei Chen ◽  
Ming Yan Wu ◽  
Zhong Fu Huang ◽  
Yi Ding ◽  
Feng Ze Dai
Keyword(s):  
Finite Element Analysis ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Strain Path ◽  
Forming Process ◽  
Element Analysis ◽  
Design Rules ◽  
Forming Quality ◽  
Metal Forming Process

It is well known that the design of multi-step sheet metal forming process is rather difficult. Even small errors may cause significant quality problem. In recent years, finite element analysis (FEA) has being considered as an essential tool for the design. Using a commercial FEA package, DYNAFORM, this paper studies the design of multi-step sheet metal forming processes, especially on how the design of the intermediate steps affect the forming quality. For a rectangle box with a rectangle protrusion inside, several different forming schemes are investigated by means of FEA. The study reveals that the strain path plays an important role. Accordingly, a couple of design rules are suggested.

scholarly journals Laser Welding of High-strength Aluminium Alloys for the Sheet Metal Forming Process

Procedia CIRP ◽  
2014 ◽  
Vol 18 ◽  
pp. 203-208 ◽  
Author(s):  
J. Enz ◽  
S. Riekehr ◽  
V. Ventzke ◽  
N. Sotirov ◽  
N. Kashaev
Keyword(s):  
Laser Welding ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Aluminium Alloys ◽  
High Strength ◽  
Forming Process ◽  
Metal Forming Process

scholarly journals Methods of determination of frictional resistances in sheet metal forming of car body sheets

2018 ◽  
Vol 19 (6) ◽  
pp. 756-760
Author(s):  
Tomasz Trzepieciński ◽  
Irena Nowotyńska
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Complex Function ◽  
Forming Process ◽  
The Coefficient Of Friction ◽  
Displacement Speed ◽  
Almost All ◽  
Lubrication Conditions

The friction phenomenon existed in almost all plastic working processes, in particular sheet metal forming, is a complex function of the material's properties, parameters of the forming process, surface topography of the sheet and tools, and lubrication conditions. During the stamping of the drawpieces there are zones differentiated in terms of stress and strain state, displacement speed and friction conditions. This article describes the methods for determining the value of the coefficient of friction in selected areas of sheet metal and presents the drawbacks and limitations of these methods.

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