Press Forging Forming of Stepped Holes in Thick Sheet Metal

2013 ◽  
Vol 706-708 ◽  
pp. 234-237
Author(s):  
Xu Jun Cao ◽  
Ke Sheng Wang ◽  
Yu Han ◽  
Chong Chao Lin
Keyword(s):  
Sheet Metal ◽  
Effective Strain ◽  
Extrusion Process ◽  
Thick Sheet ◽  
Element Analysis ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Thick Sheet Metal ◽  
Deform 3D ◽  
Good Agreement

Press forging forming of thick sheet metal is a combined extrusion process, which is put forward in the presently study. A new technological scheme for a two-step press forging of stepped holes in a thick metal sheet was proposed. Finite element analysis on the two-step process is carried out by using DEFORM-3D. Distributions of effective strain and effective stress were obtained. The study showed that the process not only can form the stepped holes, but also can increase the surface quality and strength of stepped holes in sheet metal parts, According to the numerical simulations process parameter, an experimental die was designed, the simulation results were in good agreement with the experimental data.

Numerical Simulation of Cold Press Forging Forming for Stepped Hole of Thin Sheet Metal

2011 ◽  
Vol 121-126 ◽  
pp. 249-253
Author(s):  
Ke Sheng Wang ◽  
Jian Lin Liu ◽  
Xiao Wei Chen
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Thin Sheet ◽  
Effective Strain ◽  
Optimum Process ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Thin Sheet Metal ◽  
Deform 3D ◽  
Good Agreement

An optimum process for a two-step press forging of stepped holes in a metal sheet was proposed .Numerical simulation on the two-step process was carried out by using DEFORM-3D. Distributions of effective strain and effective stress were obtained. The study showed that the process not only can form the stepped, but also can increase the surface quality and strength of stepped holes in sheet metal parts, According to the numerical simulation’s process parameter , an experimental die was designed, the simulation results were in good agreement with the experimental data

Study on a New Technological Scheme for Cold Press Forging Forming of Step Holes in Thick Sheet Metal

2011 ◽  
Vol 109 ◽  
pp. 187-190
Author(s):  
Jian Lin Liu ◽  
Ke Sheng Wang ◽  
Xiao Wei Chen
Keyword(s):  
Experimental Data ◽  
Sheet Metal ◽  
Technological Scheme ◽  
Thick Sheet ◽  
Element Analysis ◽  
Step Process ◽  
Cold Press ◽  
Thick Sheet Metal ◽  
Deform 3D ◽  
Good Agreement

An new technological scheme for a two-step cold press forging of step holes in a thick metal sheet was proposed . Finite element analysis on the two-step process is carried out by using DEFORM-3D. Velocity shade contours are obtained. The study shows that the technique can form step holes in thick sheet metal and increase their strength, According to the numerical simulation’s process parameter, an experimental die is designed, the FEA results are in good agreement with the experimental data.

Optimisation of Springback Predicted by Experimental and Numerical Approach by Using Response Surface Methodology

2005 ◽  
Vol 6-8 ◽  
pp. 753-762
Author(s):  
R. Bahloul ◽  
Phillippe dal Santo ◽  
Ali Mkaddem ◽  
A. Potiron
Keyword(s):  
Response Surface ◽  
Sheet Metal ◽  
Design Method ◽  
Fem Simulation ◽  
Numerical Approach ◽  
Tool Geometry ◽  
Nose Radius ◽  
Element Analysis ◽  
Metal Parts ◽  
Sheet Metal Parts

Bending has significant importance in the sheet metal product industry. Moreover, the springback of sheet metal should be taken into consideration in order to produce bent sheet metal parts within acceptable tolerance limits and to solve geometrical variation for the control of manufacturing process. Nowadays, the importance of this problem increases because of the use of sheet-metal parts with high mechanical characteristics (High Strength Low Alloy steel). This work describes robust methods of predicting springback of parts in 3D modelling subjected to bending and unbending deformations. Also the effects of tool geometry in the final shape after springback are discussed. The first part of this paper presents the laboratory experiments in wiping die bending, in which the influence of process variables, such as die shoulder radius, punch-die clearance, punch nose radius and materials properties were discussed. The second part summarises the finite element analysis by using ABAQUS software and compares these results with some experimental data. It appeared that the final results of the FEM simulation are in good agreement with the experimental ones. An optimisation methodology based on the use of experimental design method and response surface technique is proposed in the third part of this paper. That makes it possible to obtain the optimum values of clearance between the punch and the die and the optimum die radius which can reduce the springback without cracking and damage of product.

Deformable Sheet Metal Fixturing: Principles, Algorithms, and Simulations

1996 ◽  
Vol 118 (3) ◽  
pp. 318-324 ◽  
Author(s):  
W. Cai ◽  
S. J. Hu ◽  
J. X. Yuan
Keyword(s):  
Sheet Metal ◽  
Rigid Bodies ◽  
Fixture Design ◽  
Total Deformation ◽  
Element Analysis ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Manufacturing Operations ◽  
Nonlinear Programming Methods ◽  
Simulation Package

Fixture design is an important consideration in all manufacturing operations. Central to this design is selecting and positioning the locating points. While substantial literature exists in this area, most of it is for prismatic or solid workpieces. This paper deals with sheet metal fixture design. An “N-2-1” locating principle has been proposed and verified to be valid for deformable sheet metal parts as compared to the widely accepted “3-2-1” principle for rigid bodies. Based on the “N-2-1” principle algorithms for optimal fixture design are presented using finite element analysis and nonlinear programming methods to find the best “N” locating points such that total deformation of the deformable sheet metal is minimized. A simulation package called OFixDesign is introduced and numerical examples are presented to validate the “N-2-1” principle and optimal sheet metal fixture design approach.

FE Simulation of Sheet Metal Forming – State of the Art in Automotive Industry

2005 ◽  
Vol 6-8 ◽  
pp. 13-18 ◽  
Author(s):  
H.J. Haepp ◽  
M. Rohleder
Keyword(s):  
Sheet Metal ◽  
Automotive Industry ◽  
Development Process ◽  
High Strength Steels ◽  
Feasibility Studies ◽  
High Strength ◽  
Element Analysis ◽  
Early Design ◽  
Metal Parts ◽  
Sheet Metal Parts

Nowadays feasibility studies using finite element analysis are performed in very early design phases of sheet metal parts forming. Further, simulation technology is used to optimize the first forming stage. Because of the ever intensifying international competition and the increased use of high-strength steels and aluminum alloys, the absorption of springback deviations is a great challenge, especially in the automotive industry. The application of numerical computation to predict springback deviations and to create compensated die designs in early design phases of sheet metal parts forming becomes essential. At DaimlerChrysler the numerically based compensation of springback deviations during the die development process of complex car parts is achieved. However, developments to optimize and compensate dies automatically or to predict form deviations on assemblies are still necessary.

Location optimization of interchangeable parts in sheet metal assembly

2016 ◽  
Vol 232 (10) ◽  
pp. 1848-1857
Author(s):  
Honglun Huan
Keyword(s):  
Sheet Metal ◽  
Complete Bipartite Graph ◽  
Perfect Match ◽  
Prediction Method ◽  
Stiffened Panel ◽  
Flexible Beam ◽  
Element Analysis ◽  
Location Optimization ◽  
Metal Parts ◽  
Sheet Metal Parts

Stiffened panel is a kind of structure that is widely used in aviation manufacturing. Some sheet metal parts in the structure have three characteristics: place-interchangeable, large quantity and stochastic variation caused by spring back or distortion in manufacturing process, which prominently impacts the assembly variation. In order to minimize the influence and improve the assembly quality of stiffened panel, a model based on flexible beam is established and a simplified and approximate assembly variation prediction method is obtained. Furthermore, for the interchangeable sheet metal parts, the assembly location optimization method based on the algorithm of perfect match of weighted complete bipartite graph is proposed. At last, case study on a fuselage panel assembly is implemented. The finite element analysis results show the reliability of the simplified variation prediction method and the necessity of assembly location optimization.

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