Investigation into Influence of Pre-Forming Depth on Multi-Stage Hydrodynamic Deep Drawing of Thin-Wall Cups with Stepped Geometries

2012 ◽  
Vol 457-458 ◽  
pp. 1219-1222 ◽  
Author(s):  
Yu Zhu ◽  
Min Wan ◽  
Ying Ke Zhou ◽  
Qing Hai Liu ◽  
Nan Song Zheng ◽  
...  
Keyword(s):  
Deep Drawing ◽  
Failure Modes ◽  
Thickness Distribution ◽  
Steel Part ◽  
Drawing Ratio ◽  
Thin Wall ◽  
Forming Process ◽  
Hydrodynamic Deep Drawing ◽  
Multi Stage ◽  
Thin Walled

Hydrodynamic deep drawing (HDD) is an effective method for manufacturing complicated and thin-walled parts. Aiming at the forming process of the stainless steel part with 0.4 mm thick and complex stepped geometries, the technology scheme of multi-stage HDD assisted by conventional deep drawing (CDD) is proposed in consideration of wrinkling and destabilization in the unsupported region of the conical wall, and finite element models are built. As a key process parameter, pre-forming depth on the quality of the parts is explored with assistance of numerical simulations and verification experiments. Furthermore, the failure modes, including wrinkling and fracture during forming process are discussed; meanwhile, the optimum pre-forming depth is realized. The results indicate that the technological method is proven to be feasible for integral forming of thin-walled parts with a large drawing ratio and stepped geometries; moreover, the parts with uniform thickness distribution and high quality are successfully formed by adopting optimum pre-forming depth.

Investigation into Influence of Pre-Forming Depth on Multi-Stage Hydrodynamic Deep Drawing of Thin-Wall Cups with Stepped Geometries

2012 ◽  
Vol 457-458 ◽  
pp. 1219-1222
Author(s):  
Yu Zhu ◽  
Min Wan ◽  
Ying Ke Zhou ◽  
Qing Hai Liu ◽  
Nan Song Zheng ◽  
...  
Keyword(s):  
Deep Drawing ◽  
Thin Wall ◽  
Hydrodynamic Deep Drawing ◽  
Multi Stage

scholarly journals Investigation of a Modified Hydrodynamic Deep Drawing Assisted by Radial Pressure with Inward Flowing Liquid Process

2018 ◽  
Vol 190 ◽  
pp. 09003
Author(s):  
Maziar Khademi ◽  
Milad Sadegh yazdi ◽  
Mohammad Bakhshi-Jooybari ◽  
Hamid Gorji
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Radial Pressure ◽  
Drawing Ratio ◽  
Cavity Pressure ◽  
Flowing Liquid ◽  
Hydrodynamic Deep Drawing ◽  
Simultaneous Control ◽  
Die Set ◽  
Cylindrical Parts

Hydrodynamic Deep Drawing (HDDRP), the combination of hydroforming and conventional deep drawing, accommodates the advantages of the two processes. A technique, called HDDRP with inward flowing liquid, has been introduced based on the idea of insertion of radial pressure around the blank rim. The radial pressure created on the blank edge, can increase the drawing ratio. Thus, increasing the radial pressure to an amount greater than the cavity pressure, and independent control of these pressures is the basic idea of this research for forming cylindrical parts. To perform the experiments, two independent pumps were used to provide the two pressures independently. The pressure supply system and the die set were designed in a way that provides simultaneous control of the pressures throughout the process. Then, the effects of radial pressure paths on thickness distribution of cylindrical St13 cups were investigated. In addition, a comparison between HDDRP and HDDRP with inward flowing liquid processes has been performed experimentally. Results indicated that using a higher radial pressure than the cavity pressure and controlling their values at any moment of the process enhances the thickness distribution of the formed part in all regions.

Investigation of Forming Cylindrical Parts in a Modified Hydrodynamic Deep Drawing Assisted by Radial Pressure With Inward Flowing Liquid

2017 ◽  
Vol 140 (3) ◽  
Author(s):  
Milad Sadegh Yazdi ◽  
Mohammad Bakhshi-Jooybari ◽  
Hamid Gorji ◽  
Mohsen Shakeri ◽  
Maziar Khademi
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Radial Pressure ◽  
Chamber Pressure ◽  
Drawing Ratio ◽  
Forming Force ◽  
Flowing Liquid ◽  
Hydrodynamic Deep Drawing ◽  
Study Results ◽  
Formed Part

Among the sheet hydroforming processes, hydrodynamic deep drawing (HDD) process has been used to form complex shapes and can produce parts with high drawing ratio. Studies showed that radial pressure created on the edge of the sheet can decrease the drawing force and increase drawing ratio. Thus, increasing of radial pressure to an amount greater than chamber pressure, and independent control of these pressures, is the basic idea in this study. In this research, the effect of radial and chamber pressures on formability of St13 and pure copper sheets in the process of hydrodynamic deep drawing assisted by radial pressure (HDDRP) with inward flowing liquid is investigated. Giving that a significant portion of the maximum thinning of the formed part occurs in the beginning of the process, the pressure supply system used in the experimental tests was designed in a way, which provides simultaneous control of the radial and chamber pressures throughout the process. Thickness distribution, forming force, and tensile stresses are the parameters that were evaluated in this study. Results indicated that using a higher radial pressure than the chamber pressure and controlling their values in the initial stages of the process enhances the thickness distribution of the formed part in all regions. A comparison between the thickness distribution and maximum forming force of the formed parts by the HDDRP and HDDRP with inward flowing liquid methods showed that by applying the later method, parts with more uniform thickness distribution and less maximum thinning and forming force can be achieved.

Finite Element Simulation and Experimental Study on Blow Forming of Plastic Cups

2011 ◽  
Vol 148-149 ◽  
pp. 1319-1322
Author(s):  
Xiao Hu ◽  
Yi Sheng Zhang ◽  
Hong Qing Li ◽  
De Qun Li
Keyword(s):  
Finite Element ◽  
Thickness Distribution ◽  
Viscoelastic Model ◽  
Engineering Practice ◽  
Fe Model ◽  
Thin Wall ◽  
Forming Process ◽  
Element Simulation ◽  
Physically Based ◽  
Set Up

Blow forming process of plastic sheets is simple and easy to realize, thus, it is widely used for plastic thin-wall parts. In the practical production, an effective method is needed for the preliminary set-up of process parameters in order to achieve accurate control of thickness distribution. Thus, a finite element method (FEM) code is used to simulate blow forming process. For better description of complex material theological characteristics, a physically based viscoelastic model (VUMAT forms Buckley model) to model the complex constitutive behavior is used. Nonlinear FE analyses using ABAQUS were carried out to simulate the blow forming process of plastic cups. The actual values at different locations show a satisfactory agreement with the simulation results: as a matter of fact the error along the cell mid-section did not exceed 0.02 mm on average, corresponding to 5% of the initial thickness, thus the FE model this paper can meet the requirements of the engineering practice.

scholarly journals Buckling Analysis and Section Optimum for Square Thin-Wall CFST Columns Sealed by Self-Tapping Screws

2019 ◽  
Vol 2019 ◽  
pp. 1-14
Author(s):  
He Zhang ◽  
Kai Wu ◽  
Chao Xu ◽  
Lijian Ren ◽  
Feng Chen
Keyword(s):  
Bearing Capacity ◽  
Failure Modes ◽  
Steel Plate ◽  
Local Buckling ◽  
Steel Tube ◽  
Thin Wall ◽  
Type Section ◽  
Plate Buckling ◽  
Thin Walled ◽  
Cfst Columns

Two columns of thin-walled concrete-filled steel tubes (CFSTs), in which tube seams are connected by self-tapping screws, are axial compression tested and FEM simulated; the influence of local buckling on the column compression bearing capacity is discussed. Failure modes of square thin-wall CFST columns are, first, steel tube plate buckling and then the collapse of steel and concrete in some corner edge areas. Interaction between concrete and steel makes the column continue to withstand higher forces after buckling appears. A large deflection analysis for tube elastic buckling reflects that equivalent uniform stress of the steel plate in the buckling area can reach yield stress and that steel can supply enough designing stress. Aiming at failure modes of square thin-walled CFST columns, a B-type section is proposed as an improvement scheme. Comparing the analysis results, the B-type section can address both the problems of corner collapse and steel plate buckling. This new type section can better make full use of the stress of the concrete material and the steel material; this type section can also increase the compression bearing capacity of the column.

Optimum Design of Forming Sequence of One-Piece Automobile Steel Wheels without Welding Using Finite Element Simulation

2007 ◽  
Vol 340-341 ◽  
pp. 773-778
Author(s):  
Y. Abe ◽  
J. Watanabe ◽  
Kenichiro Mori
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Optimum Design ◽  
Deep Drawing ◽  
Outer Side ◽  
Forming Process ◽  
Multi Stage ◽  
Element Simulation ◽  
Automobile Steel ◽  
The One

A forming sequence of one-piece automobile steel wheels without welding was designed. In this forming process, the one-piece wheel was formed from a circular blank only by multi-stage stamping operations, and a deeply drawn cup was formed into the wheel. Two humps of the rim flange for fixing the tire were formed in the flaring and flanging stages. The humps of the rim in the opening and outer side were formed by buckling the inner flange of the rim, and by swelling the outer flange with an upper die having a short land, respectively. In addition, the number of stages was considerably reduced from 16 stages to only 9 stages by combining the deep drawing and ironing stages and by adding a holding die in the flaring stages. The forming sequence of the one-piece wheels was evaluated by both finite element simulation and miniature experiment.

A Method of Improving Limiting Drawing Ratio：Differential Temperature Deep Drawing Based on Superplasticity

2011 ◽  
Vol 239-242 ◽  
pp. 392-397
Author(s):  
Xue Feng Xu ◽  
Ning Li ◽  
Gao Chao Wang ◽  
Hong Bo Dong
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
Coupled Analysis ◽  
Flowing Water ◽  
Finite Element Code ◽  
Uniform Thickness ◽  
Forming Process ◽  
Good Agreement

A thermal-mechanical coupled analysis of superplastic differential temperature deep drawing (SDTDD) with the MARC finite element code is performed in this paper. Initial drawing blank of an AA5083 bracket was calculated and adjusted according to the simulation result. During the SDTDD simulation, the power-law constitutive model of AA5083 was established as function of temperature and implanted in software MARC through new complied subroutine. Under the guide of the numerical simulation, the die was fabricated and the AA5083 bracket was successfully manufactured via superplastic differential temperature deep drawing. In forming practice, the temperature of female die was kept at 525°C, i.e. the optimal superplastic temperature of AA5083, and the punch was cooled by the flowing water throughout the forming process. The drawing velocity of punch was 0.1mm/s. Results revealed that the formed bracket had a sound uniform thickness distribution. Good agreement was obtained between the formed thickness profiles and the predicted ones.

Influencing Factors of AZ31B Sheet Deep Drawing

2011 ◽  
Vol 189-193 ◽  
pp. 88-91
Author(s):  
Jun Gao ◽  
Zhen Ming Yue ◽  
Shu Xia Lin
Keyword(s):  
Numerical Simulation ◽  
Deep Drawing ◽  
Experimental Approach ◽  
Elevated Temperatures ◽  
Heating Temperature ◽  
Thickness Distribution ◽  
Simulation Software ◽  
Forming Limit ◽  
Forming Process ◽  
Specific Strength

Magnesium alloys have been attracting much more attentions due to its low density, high specific strength and its lightweight during the past 30 years. In this paper, the deep drawing performance of AZ31B magnisium alloy sheets at elevated temperature was studied by the experimental approach. The results indicated that the formability of the AZ31B sheets at elevated temperatures could be improved significantly. The best external forming parameters can be obtained such as heating temperature of sheet, die-punch clearance, punch fillet radius, etc. Simulating the forming process by using the numerical simulation software, we investigated the stress-strain distribution, thickness distribution and forming limit, etc. The thickness distribution by the numerical simulation agrees well with the experimental results.

Effect of Geometries of Die/Blank Holder and Punch Radii in Angular Deep-Drawing Dies on DP Steel Formability

2015 ◽  
Vol 813-814 ◽  
pp. 269-273 ◽  
Author(s):  
P. Venkateshwar Reddy ◽  
S. Hari Prasad ◽  
Perumalla Janaki Ramulu ◽  
Sirish Battacharya ◽  
Daya Sindhu Guptha
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Frictional Coefficient ◽  
Drawing Ratio ◽  
Drawing Process ◽  
Dp Steel ◽  
Punch Force ◽  
Blank Holder ◽  
Deep Drawing Process ◽  
Drawing Dies

In recent days deep-drawing is one of the most important methods used for sheet metal forming. The geometries of die/blank holder and punch are one of the parameters for deep-drawing. This paper presents an attempt to determine the effect of different geometries of die/blank holder, punch radii and blank holding force on deep drawing process for the formability of DP Steel of 1mm sheet. The numerical simulations are performed for deep drawing of cylindrical cups at a constant frictional coefficient of 0.12 and different blank holding forces of 10, 15 and 20kN are used. For numerical simulation PAM STAMP 2G a commercial FEM code in which Hollomon’s power law and Hills 1948 yield’s criterion is used. The die/blank holder profile used with an angles of α=0°, 12.5°, 15° and die/punch profile with a radii of R= 6 and 8mm were simulated to determine the influence of punch force and thickness distribution on the limit drawing ratio. The aim of this study is to investigate the effect of tool geometries on drawability of the deep-drawing process.

Application of Viscous Pressure Forming in Aeronautics and Astronautics

2014 ◽  
Vol 989-994 ◽  
pp. 3306-3309
Author(s):  
Ji Guang Li ◽  
Jie Gang Zhang ◽  
Jing Ping Liu ◽  
Rui Feng Zhao ◽  
Yang Li ◽  
...  
Keyword(s):  
Basic Principle ◽  
High Strength ◽  
Thin Wall ◽  
Forming Process ◽  
Variable Diameter ◽  
Thin Walled ◽  
Viscous Pressure ◽  
Viscous Pressure Forming ◽  
Thin Wall Part ◽  
Super Alloy

Viscous pressure forming (VPF) is a new developed sheet soft-punch forming process in 1900s. The basic principle and characteristics of VPF are described. The applications of VPF technologies of nickel-based super-alloy corrugated thin-walled part, asymmetrical thin-wall part with variable diameter, super-alloy thin-walled part with variable diameters, corrugated thin-walled part with larger diameter and small section are presented. The results show that VPF is suitable for the forming of parts with high strength, low plasticity, super thin-wall and complex shaped.

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