Application of Separated Die Design to Production of Ecap Dies

2012 ◽  
Vol 445 ◽  
pp. 120-124 ◽  
Author(s):  
Huseyin Erol Akata
Keyword(s):  
Metal Forming ◽  
Die Design ◽  
Shear Stresses ◽  
Notch Effect ◽  
Plastic Strains ◽  
Alloy Specimen ◽  
Equal Channel Angular Processing ◽  
High Plastic ◽  
5083 Aluminum Alloy ◽  
Very High

Metal forming processes with principally shear stresses that very high plastic strains are obtained in one pass are defined as severe plastic deformation (SPD) processes. Strain values can additionally be increased with additional passes throughout the process. Equal channel angular processing (ECAP) is the most applied method among the SPD processes due to relative ease of die manufacturing. On the other hand, die failures like corner cracking are frequently observed due to high notch effect and therefore use of the dies is limited. In the presenting study multi element die design (separated die design) approach was applied to production of ECAP dies in order to eliminate die failures and 5083 Aluminum alloy specimen were deformed with several passes. Although some additional development for die arrangement and fixation are needed, corner cracking was never observed and dies could be used safely.

Forging Process Analysis of 6061 Aluminum Alloy Motorcycle Brake Parts

2021 ◽  
Vol 901 ◽  
pp. 176-181
Author(s):  
Tung Sheng Yang ◽  
Chieh Chang ◽  
Ting Fu Zhang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Metal Forming ◽  
Process Analysis ◽  
Surface Hardness ◽  
Dimensional Accuracy ◽  
Die Design ◽  
Element Analysis ◽  
Forging Process

This paper used finite element analysis of metal forming to study the forging process and die design of aluminum alloy brake parts. According to the process parameters and die design, the brake parts were forged by experiment. First, the die design is based on the product size and considering parting line, draft angle, forging tolerance, shrinkage and scrap. Secondly, the finite element analysis of metal forming is used to simulate the forging process of aluminum alloy brake parts. Finally, the aluminum alloy brake levers with dimensional accuracy and surface hardness were forged.

A New Sheet Die Design Methodology to Eliminate Scrap Shedding Problems During Mass Production

2010 ◽  
Author(s):  
Beril Gu¨mu¨s¸ ◽  
Bu¨lent Ekici
Keyword(s):  
Sheet Metal ◽  
Metal Forming ◽  
Design Methodology ◽  
Lower Cost ◽  
Dimensional Accuracy ◽  
Production Quality ◽  
Die Design ◽  
Mold Design ◽  
Manufacturing Companies ◽  
Automotive Part

Manufacturing companies need to improve their production technology with improved dimensional accuracy at lower cost in order to manufacture sheet metal based products. Scrap shedding is an issue that should be examined at the cutting and sheet metal forming operations. In order to extend the life cycle of the cutting moulds, scrap shedding should be identified. When scrap shedding has not been taken into consideration, scraps have accumulated in the moulds reducing the production quality and causing deformation of the mould, increasing the production cost by obligating to perform extra transactions. This study becomes more focused upon the analysis of scrap shedding. In order to simulate the scrap shedding LS-Dyna and Pam Stamp software have been used. For examining of the scrap shedding an automotive part was chosen. In order to realize scrap shedding having any problems, new improvements have been suggested. Design of Experiments techniques which provide important advantages to engineering studies have been examined. By means of experimental design techniques the scrap shedding design process was also added to the classical mold design approach via a less quantities of simulations.

Off-Line Testing of Tribo-Systems for Sheet Metal Forming Production

2014 ◽  
Vol 966-967 ◽  
pp. 3-20 ◽  
Author(s):  
Niels Bay ◽  
Ermanno Ceron
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Normal Pressure ◽  
Environmentally Benign ◽  
Interface Pressure ◽  
Test Conditions ◽  
Interface Contact ◽  
Very High

Off-line testing of new tribo-systems for sheet metal forming production is an important issue, when new, environmentally benign lubricants are to be introduced. To obtain useful results it is, however, vital to ensure similar conditions as in the production process regarding the main tribo-parameters, which are tool/workpiece normal pressure, sliding length, sliding speed and interface contact temperature. The paper describes a generic methodology for such tests exemplified on an industrial, multistage deep drawing example, where deep drawing is followed by two successive re-drawing operations leading to very high tool/workpiece interface pressure and temperature in the second re-draw. Under such conditions only the best lubricant systems work satisfactory, and the paper shows how the performance of different tribo-systems in production may be predicted by off-line testing combined with numerical modelling in order to ensure proper test conditions.

Modification Strain-Based Failure Assessment Diagram for High Strength Pipeline Steel

2016 ◽  
Vol 853 ◽  
pp. 33-40
Author(s):  
Jun Lin Shi ◽  
Jian Ping Zhao ◽  
Wei Jie Jiang
Keyword(s):  
Finite Element ◽  
Material Properties ◽  
Pipeline Steel ◽  
High Strength ◽  
Plastic Strains ◽  
Failure Assessment Diagram ◽  
Failure Assessment ◽  
High Plastic

The strain-based failure assessment diagram (SB-FAD) has been developed to predict failure due to high plastic strains. This paper validates the SB-FAD by finite element results for high strength pipeline steel (X80, X80HD, and X90) with four representative specimens (CT, CCP, DECP, and SCEP) of different crack sizes, respectively. The influence of material properties, geometries and crack sizes on failure assessment curves were compared and analyzed. Meanwhile, the modified Option-1 curve of SB-FAD is given in this paper. The results showed that the modified Option-1 curve of SB-FAD is more accurate when the value of abscissais Dr small and more conservative when the value of abscissa Dr is large.

506 Notch effect of bearing steel SUJ2 in very high cycle regime

2006 ◽  
Vol 2006.55 (0) ◽  
pp. 201-202
Author(s):  
Keisuke TANAKA ◽  
Nobuyuki MIYAMOTO ◽  
Hirotaka TSURU ◽  
Yoshiaki AKINIWA
Keyword(s):  
Bearing Steel ◽  
Notch Effect ◽  
Very High
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