In-Process Visualisation for Deformation Monitoring and Analysis of Sheet Metal Forming Processes

2013 ◽  
Vol 677 ◽  
pp. 384-387 ◽  
Author(s):  
Wai Kei Ricky Kot ◽  
Luen Chow Chan
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Deformation Process ◽  
Deformation Monitoring ◽  
Displacement Sensor ◽  
Laser Displacement Sensor ◽  
Profile Data ◽  
Profile Change

In this paper, a visualisation system will be discussed that can be used to capture the deformation profile of the sheet blank during sheet metal forming processes, such as deep drawing and shape forming. The visualisation system utilizes a 2D laser displacement sensor for deformation profile acquisition. The sensor is embedded in the die and the laser propagates through the die to detect the profile change of the specimen concealed in the die during operation. The captured profile data will be collected, manipulated and transferred to a monitor for display via a controller. This visualisation of the deformation profile will provide engineers and researchers with an intuitive means of analysing and diagnosing the deformation process during sheet metal forming.

Multi-Step Forward Finite Element Method for the Numerical Simulation of Sheet Metal Forming

2011 ◽  
Vol 474-476 ◽  
pp. 251-254
Author(s):  
Jian Jun Wu ◽  
Wei Liu ◽  
Yu Jing Zhao
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Mapping Method ◽  
Constitutive Relationship ◽  
Element Method

The multi-step forward finite element method is presented for the numerical simulation of multi-step sheet metal forming. The traditional constitutive relationship is modified according to the multi-step forming processes, and double spreading plane based mapping method is used to obtain the initial solutions of the intermediate configurations. To verify the multi-step forward FEM, the two-step simulation of a stepped box deep-drawing part is carried out as it is in the experiment. The comparison with the results of the incremental FEM and test shows that the multi-step forward FEM is efficient for the numerical simulation of multi-step sheet metal forming processes.

Mg sheet metal forming: Lessons learned from deep drawing Li and Y solid-solution alloys

JOM ◽  
2006 ◽  
Vol 58 (5) ◽  
pp. 62-69 ◽  
Author(s):  
Sean R. Agnew ◽  
Jeremy W. Senn ◽  
Joseph A. Horton
Keyword(s):  
Solid Solution ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Lessons Learned

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.

scholarly journals Modelling real contact areas caused by material straining effects in sheet metal forming simulation

2021 ◽  
Author(s):  
Peter Essig ◽  
Mathias Liewald ◽  
Maximilian Burkart ◽  
Maxim Beck
Keyword(s):  
Sheet Metal ◽  
Surface Pressure ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Sheet Metal Part ◽  
Metal Part ◽  
Forming Simulation ◽  
Contact Areas ◽  
Surface Pressure Distribution

Shortened product development processes in automotive industry combined with the upcoming lack of experts do challenge sheet metal part production fundamentally. Tryout time and manufacturing costs of large forming dies today are significantly influenced by their digitally supported engineering. The forming process by such tools is beside other influences is affected by elastic deformations of forming dies and press structure as well as contact areas between die and sheet metal part. In deep drawing such contact areas are influenced by the blank properties and the flange behavior in terms of thickening and thinning. Recent developments in sheet metal forming simulation do consider advanced friction models and structural modeling of die and press components improving simulation accuracy. Nevertheless thinning or thickening of sheet metal results into localized surface pressure distribution during deep drawing. For this reason, it is not sufficient to use the currently common practice of homogeneous surface pressure distribution in sheet metal forming simulation. In this respect, this paper presents a numerical approach for consideration of straining effects in the sheet metal part during forming operation. For this purpose, a systematic process improvement was developed in this paper to identify contact areas via a numeric simulation parameter. Validating the numerical investigation, a rectangle cup die is used, considering major strain. The main results of this contribution for that reason show how simulated contact areas can be estimated by reverse engineering of real forming parts. Hereby straining based contact areas lead to a novel contact area design in process planning, resulting in efficient die tryout.

Simulation Study of Deep Drawing Process

2020 ◽  
Vol 977 ◽  
pp. 139-147
Author(s):  
Jaber Abu Qudeiri ◽  
Aiman Ziout ◽  
Muneir Alsayyed ◽  
Ammar Alzarooni ◽  
Faris Safieh ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Process Parameters ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Deformation Behaviour ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Optimal Values

Deep drawing process is one of the important processes in sheet metal forming. One of the challenge that faces the deep drawing process is selecting the optimal values of process parameters for the deep drawing process. In order to find the optimum values of these parameters, it is necessary to study their influence on the deformation behaviour of the sheet metal. This paper develops a simulation model for deep drawing process based on Simufact sheet metal forming module to study the effect process parameters on the deep-drawing characteristics. The study also obtained the distribution of strain on the drawn product. Three process parameters are considered in this study namely, punch radius, die radius and clearance, the effect of these process parameter on the required force as well as on the quality of the product are investigated.

scholarly journals A new approach for dry metal forming: CO2 as volatile lubrication in combination with hard and low friction coatings

2018 ◽  
Vol 190 ◽  
pp. 14012
Author(s):  
Georg Umlauf ◽  
Henning Hasselbruch ◽  
Jan Hinnerk Henze ◽  
Jakob Barz ◽  
Andreas Mehner
Keyword(s):  
Tool Wear ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Coating System ◽  
Hybrid Technology ◽  
Dry Process ◽  
Novel Approach ◽  
The One

Nowadays, it is more important than ever to meet the increasing technical and statutory requirements and to develop new process strategies. In sheet metal forming the low consumption of oil lubrication gets an increasingly important role. The aim in sheet metal forming is to reduce the amounts of lubricants. In the long term, the future sheet metal processing should be able to completely dispense without mineral oil-containing lubricants. Two promising approaches for a dry process design are combined in this paper for the first time and the fundamental feasibility of this new hybrid technology is shown. On the one hand, a novel approach for temporary lubrication of deep-drawing processes with CO2 as a volatile medium is used. On the other hand, it is supported by the application of an additional hard coating system such as a silicon nitride (Si3N4) or tungsten doped a-C:H multilayered (Cr/CrNx/a-C:H:W/a-C:H) coating system to further reduce tool wear and wear debris of the formed sheets made of DC04 (mat. no.: 1.0338). The results show a low coefficient of friction and reduced wear. Especially for the carbon coating system, there is minor tool wear at a higher surface pressure. By means of the graphite constituent, even a smoothening of the roughness peaks can be recorded. The next step would be the implementation of this hybrid technology on a tool for deep drawing a rectangular cup.

Improving the Quality in Deep Drawing of Rectangle Parts Using Variable Blank Holder Force

2010 ◽  
Vol 37-38 ◽  
pp. 521-524
Author(s):  
Yu Qing Shi
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Failure Modes ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Variable Blank Holder Force

Wrinkling and tearing are the main failure modes in sheet-metal forming. Wrinkle may occur at the start of a punch stroke if the blank-holder force (BHF) is too low, and tearing may occur at the end of a stroke if the BHF is too high. The BHF is important for deep-drawing because of an effective way to promote deep formability sheet metal. They can be reduced or eliminated by manipulating a suitable BHF during sheet-metal forming. This paper presented an attempt to determine the effect of variable BHF on the tearing and wrinkling and investigated using 08Al sheet metal. The experiment show that tearing and wrinkling can be eliminated and the quality of deep drawing of rectangle parts can be improved using variable BHF.

Sign in / Sign up

Export Citation Format

Share Document