Reducing Non-Value Added Process for an Automotive Component Using Finite Element Modeling

2012 ◽  
Vol 576 ◽  
pp. 737-741
Author(s):  
Roseleena Jaafar ◽  
Farrahshaida Mohd Salleh ◽  
Izdihar Tharazi ◽  
Abdul Rahman Omar
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Sheet Metal ◽  
Research Work ◽  
Value Added ◽  
Forming Limit ◽  
Low Carbon ◽  
Forming Process ◽  
Automotive Component ◽  
Element Modeling

The research work focuses on sheet metal stamping process simulation of an automotive component known as bracket assembly upper spring made from low carbon steel and has axis-symmetrical cup shape that employs four multi-stage drawing processes. Non-value added drawing stages (optimization process) reduced and portrayed from the formability simulation result using finite element modeling (FEM) method. The modified design, with reduction of one draw stage, showed that the risk of the component to form cracks is lesser, the material elements are further away from the failure zone of the forming limit diagram (FLD) and it meets the requirement for minimum thickness. The FEM simulation was able to predict the formability and optimize the design of a sheet metal forming process that lowered the product cost and improve cycle time.

scholarly journals Experimental And Theoretical Determination Of Forming Limit Curve

2015 ◽  
Vol 60 (3) ◽  
pp. 1881-1886
Author(s):  
J. Adamus ◽  
K. Dyja ◽  
M. Motyka
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Fracture Initiation ◽  
Forming Limit ◽  
Forming Process ◽  
Element Analysis ◽  
Metal Forming Process

Abstract The paper presents a method for determining forming limit curves based on a combination of experiments with finite element analysis. In the experiment a set of 6 samples with different geometries underwent plastic deformation in stretch forming till the appearance of fracture. The heights of the stamped parts at fracture moment were measured. The sheet - metal forming process for each sample was numerically simulated using Finite Element Analysis (FEA). The values of the calculated plastic strains at the moment when the simulated cup reaches the height of the real cup at fracture initiation were marked on the FLC. FLCs for stainless steel sheets: ASM 5504, 5596 and 5599 have been determined. The resultant FLCs are then used in the numerical simulations of sheet - metal forming. A comparison between the strains in the numerically simulated drawn - parts and limit strains gives the information if the sheet - metal forming process was designed properly.

scholarly journals Finite Element Modeling of Stamp Forming Process on Fiber Metal Laminates

2015 ◽  
Vol 03 (03) ◽  
pp. 247-252 ◽  
Author(s):  
Xiaocen Dou ◽  
Sivakumar Dhar Malingam ◽  
Jae Nam ◽  
Shankar Kalyanasundaram
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Forming Process ◽  
Fiber Metal Laminates ◽  
Element Modeling ◽  
Stamp Forming ◽  
Fiber Metal

Influence of Process Parameters on Electric Upsetting Process by Using Finite Element Modeling

2017 ◽  
Vol 728 ◽  
pp. 42-47 ◽  
Author(s):  
Pattarapong Nuasri ◽  
Yingyot Aue-u-Lan
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Material Flow ◽  
Electric Heating ◽  
Heating System ◽  
Forming Process ◽  
Influence Of Process Parameters ◽  
Element Modeling ◽  
Electric Upsetting ◽  
The Relationship

Electric Upsetting Process (EUP) is a process combining the forming process with the electric heating system. It is commonly used to manufacture a preform of a bar with high upsetting ratio, such as an axial shaft. The reliable forming process requires the understanding the effect of process and electrical parameters. Currently, the designer develops this process by trail-and-error. To successfully develop this process, the relationship between the electric heating and the forming parameters needs to be clearly understood. In this study, three parameters are investigated; namely anvil speed, upsetting load and heating voltage. Finite Element Modeling (FEM) is used as a tool for evaluating these parameters. The FEM results indicate that those parameters play significant roles on the material flow as well as the heating characteristics (i.e. temperature distributions and heat flow).

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