Numerical Simulation of Sheet Metal without Burr in the Process of Blanking Based on DEFORM for Manufacturing Engineering

2012 ◽  
Vol 583 ◽  
pp. 276-280
Author(s):  
Shu Tian Fan ◽  
Yong Wu
Keyword(s):  
Numerical Simulation ◽  
Stainless Steel ◽  
Sheet Metal ◽  
Cross Section ◽  
Important Application ◽  
Manufacturing Engineering ◽  
Deform 2D ◽  
Two Stages ◽  
Blanking Process

A blanking method which can punch the sheet metal without burr is presented, this method is divided into two stages: preloading deformation and blanking. And the FEM software DEFORM-2D is used to simulate the blanking process of burr-free of stainless steel AISI304. By changing the size of relative clearance, analyzing the quality of cross-section and blanking process. The result shows that the clearance has an effect on blanking force and the length of shear zone. which provides the certain fundamental for predicting the defects of blanking pieces and designing the molds. And this method has an important application value in manufacturing engineering.

Simulated Analysis of Flow and Deformation in Trilateral Constrained and Asymmetric Square Cup Deep-Drawing

2011 ◽  
Vol 199-200 ◽  
pp. 1901-1905
Author(s):  
Li Cheng Huang ◽  
Xiao Ting Xiao ◽  
Li Guang Tan ◽  
Guo Liang Li
Keyword(s):  
Numerical Simulation ◽  
Stainless Steel ◽  
Friction Coefficient ◽  
Sheet Metal ◽  
Deep Drawing ◽  
Sheet Metal Part ◽  
Metal Part ◽  
Forming Quality ◽  
Simulated Analysis

To satisfy the local forming need of sheet-metal part, numerical simulation of SUS304 stainless steel deep-drawing with trilateral constrained slot were carried out by employing the analytical software ETA/dynaform5.5. The influence of different friction coefficient and holder force on the forming quality was analyzed by taking the inflow volume while parts forming 50mm as standard. The results show that the effect of trilateral constraint on the uneven flow and deformation of flange. And some measures were illustrated to improve the quality of some of these parts.

Numerical Simulation of Forming Process for Cover with Stiffening Components Made of Grade 2 Titanium Sheet Metal

2016 ◽  
Vol 687 ◽  
pp. 206-211
Author(s):  
Wojciech Więckowski
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Empirical Studies ◽  
Strength Properties ◽  
Forming Process ◽  
Titanium Sheet ◽  
Plastic Properties ◽  
Fem Method

This study presents the findings of numerical simulations of forming process for an inspection hole cover with stiffening ribs made of thin grade 2 titanium sheet metal. The numerical simulation was carried out using the FEM method with PAMStamp 2G software. Numerical calculations were performed with consideration for the phenomenon of material strain hardening and anisotropy of plastic properties of the sheet metal formed. Properties of the grade 2 titanium alloy analysed in the simulations were adopted based on the results of the empirical studies. Adequate parameters of the forming process were selected in order to eliminate unfavourable phenomena of losing of material coherence and sheet metal wrinkling. The effect of conditions of friction between the sheet metal and tool and pressure force of the blank holder on the forming process was investigated. The analysis of the distribution of plastic strain and reduction in wall thickness of the drawn parts can be used for determination of the effect of changes in selected parameters and orientation of the specimen on the process of drawn part forming. The quality of drawn parts was assessed based on the shape inaccuracy determined during simulation of forming. The inaccuracy depended on the conditions of the process and strength properties of the titanium sheet metal.

Numerical Analysis for Multi-Point Forming of Aluminum Alloy Profile

2014 ◽  
Vol 1035 ◽  
pp. 128-133 ◽  
Author(s):  
Xue Zhi Liu ◽  
Chun Guo Liu ◽  
Yuan Yao ◽  
Xue Guang Zhang
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Numerical Analysis ◽  
Sheet Metal ◽  
Cross Section ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Bending Process ◽  
A New Technique ◽  
Elastic Cushion

As a new technique to form sheet metal parts, Multi-point forming (MPF) also can be used on bending aluminum alloy profile. Since the Multi-Point Die (MPD) which replaces the traditional solid bending die is composed of many discrete punch elements, dimples always occur on the plate of profiles. To eliminate the dimpling defects, numerical simulation of the bending process with A6N01S-T5 aluminum alloy hollow profile using MPD were conducted. By comparing the bending effects on MPD with different size of punch elements and with different kind of elastic cushion, reasonable forming parameters were obtained. Pressing of Aluminum alloy profile with different radii on the MPD and solid die were simulated. The cross-section distortion indicated that the aluminum alloy profile can be formed with MPF technique while it has the advantage of flexibility. For the profile with large deformation, multi-step MPF method is a better choice due to its rapid reconfigurable characteristic.

Numerical Simulation of the Effect of Punch Paths on the Quality of Sheet Metal Stretch Forming

2012 ◽  
Vol 217-219 ◽  
pp. 2002-2005
Author(s):  
Chang Jiang Wang ◽  
Diane J Mynors ◽  
Tarsem Sihra
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Finite Element Modelling ◽  
Metal Strip ◽  
Stretch Forming ◽  
Forming Quality ◽  
Element Modelling

Presented here is the simulation of uniaxial stretch forming using two punches in a sheet metal forming operation. In the finite element modelling, the sheet metal strip was held by two bank holders and two punches are able to move in two directions to stretch the sheet metal. Due to the friction between the punch and sheet metal, it was found that friction affects the sheet metal forming quality, however by adopting an optimal punch path the effect of friction in sheet metal forming can be reduced. The effect of punch paths on the quality of the sheet metal are also reported in this paper.

Improving the Cut Edge by Counter-Shaving

2007 ◽  
Vol 344 ◽  
pp. 217-224 ◽  
Author(s):  
Hartmut Hoffmann ◽  
Florian Hörmann
Keyword(s):  
Sheet Metal ◽  
Research Work ◽  
Dimensional Accuracy ◽  
Burr Formation ◽  
Cut Edge ◽  
Edge Quality ◽  
Metal Materials ◽  
The Right ◽  
Two Stages

In blanking operations the cut edge of the sheet metal is not clear due to fracturing and burr formation by the shearing process. For precision parts with high quality and dimensional accuracy, often secondary machining is necessary. Shaving, in particular, counter-shaving, is a shearing operation to improve the cut edge quality of a blanked part or punched hole in two stages. This paper introduces a progressive die tool to realize the counter-shaving process on a single acting press. In order to realize the shaving operation in the opposite punching direction, the punch needs to move in counter direction. The burr and fracture zone left on the sheet metal after the first stage will be removed by the counter-shaving operation. By choosing the right process parameter a sharpedge transition is formed, without any rollover, between the upper surface of the sheet metal and the sheared-edge. Different punch geometries as well as the corresponding process parameters were part of the research work in order to improve the cut edge. Experimental and FEM results are presented for two sheet metal materials at three thicknesses.

Simulation on temperature fields and phase transformation of 316L stainless steel tubes during Orbital – TIG auto welding process

2021 ◽  
Vol 95 ◽  
pp. 2-10
Author(s):  
Manh Ngo Huu ◽  
Keyword(s):  
Numerical Simulation ◽  
Stainless Steel ◽  
Phase Transformation ◽  
316L Stainless Steel ◽  
Welding Process ◽  
Temperature Fields ◽  
Heat Distribution ◽  
Steel Tubes ◽  
Steel Pipes

Orbital - TIG (OT) auto welding process was applied for the weld connection of the fixed pipe lines. The heat distribution of the OT welding has influenced phase transformation and quality of the weld. In this paper, the temperature fields and phase transformation of 316L stainless steel pipes have been simulated during OT auto welding process. The numerical simulation has been used and supported by the JMATPRO 7.0 and SYSWELD softwares.

Numerical simulation of sheet metal blanking based on fully coupled elastoplasticity-damage constitutive equations accounting for yield surface distortion-induced anisotropy

2016 ◽  
Vol 26 (7) ◽  
pp. 1061-1079 ◽  
Author(s):  
Zhenming Yue ◽  
Houssem Badreddine ◽  
Khemais Saanouni ◽  
Xincun Zhuang ◽  
Jun Gao
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Yield Surface ◽  
Kinematic Hardening ◽  
Induced Anisotropy ◽  
Surface Distortion ◽  
Edge Quality ◽  
Blanking Process ◽  
Fully Coupled ◽  
Yield Surface Distortion

This paper deals with the numerical simulation of sheet metal blanking process based on fully coupled elastoplastic model accounting for the induced anisotropies due to the kinematic hardening and the yield surface distortion. The yield surface distortion is assumed to be controlled by the kinematic hardening leading additional extra hardening which enhances the predictive capabilities of the model. Series of finite element-based numerical simulations of blanking process with four kinds of assumed distortional hardening parameters have been conducted. Through the comparison between the experimentally observed responses and the numerically predicted ones with and without the yield surface distortion effect, the significance of the yield surface distortion-induced anisotropy on the estimation of the blanking edge quality has been investigated.

Application of Fine Blanking to the Manufacture of a Sprocket with Stainless Steel Sheet

2004 ◽  
Vol 261-263 ◽  
pp. 1665-1670 ◽  
Author(s):  
Y.H. Seo ◽  
Byoung Kee Kim ◽  
H.D. Son
Keyword(s):  
Stainless Steel ◽  
Unit Cost ◽  
Damage Model ◽  
Hardness Test ◽  
Simple Method ◽  
Fine Blanking ◽  
3 Dimensional ◽  
Deform 2D ◽  
Die Roll ◽  
Blanking Process

Wire cutting(EDM) or blanking is used to made workpieces from sheet metal. Wire EDM provides a relatively simple method for making holes of any desired cross section in material. But EDM requires a lot of working time and the high unit cost of production. In conventional blanking, for the production of precision devices or assemblies, it is always necessary that at least two, but generally more, secondary operations are required per piece part. Using the fine blanking process, a precise finished part with inner and outer forms clearly sheared over the whole material thickness are produced in one single operation. In this study an attempt is made to manufacture a sprocket with fine blanking process. The sprocket is parts for the tape feeder of surface mount system in electronic parts. First, a change of the existing design is made in a sprocket. The materials selected are three kinds of stainless steel, SUS304, SUS316 and SUS430. And the mechanical properties are investigated through the tensile test. After fine blanking, hardness and precision are examined with hardness test and 3-dimensional coordinate measuring for samples. The results of investigations of fine-blanking process with the help of FEM code, DEFORM 2D, are presented. For the simulation, SUS304 and SUS316 are used as materials. The damage model of Cockroft and Latham is used to calculate damage. Die-roll height, die-roll width, burnish zone and fracture zone from the fine blanking simulation are investigated in comparison with them of samples. And the applied force at each part of fine-blanking die is estimated with load-stroke diagram.

Effects of Hole Geometry on Film Coverage and Cooling Capability

2004 ◽  
Author(s):  
J. T. Liu ◽  
X. F. Peng
Keyword(s):  
Numerical Simulation ◽  
Cross Section ◽  
Film Cooling ◽  
Comprehensive Evaluation ◽  
Constant Cross Section ◽  
Shaped Hole ◽  
Hole Geometry ◽  
Definition Of ◽  
Compound Angle

A numerical simulation was conducted to investigate the film effectiveness of film cooling using a single hole with two types of geometry: cylindrical hole with constant cross section and shaped hole with conically widened exit. The film cooling jet was injected through a 30° inclined hole to the surface and with lateral directions of 0°, 45° and 90°, for the blowing rates of 0.5, 1.0 and 2.0, respectively. The film effectiveness analyzing method was discussed based on the simulation. An effort is performed to form a more comprehensive evaluation technology with the definition of three parameters, film coverage, average cooling capability and uniformity of film. The results indicate that the film quality of compound angle injection depends on the equilibrium between the lateral and axial momentum components of coolant jet, and that the film protects the surface effectively at moderate blowing rate. The use of a shaped hole shows noticeable advantage.

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