Research on Stamping of Aluminum Alloy Hemispherical Components Based on Numerical Simulation and Experiments

2010 ◽  
Vol 97-101 ◽  
pp. 236-239
Author(s):  
Cheng Jun Han ◽  
Xin Bo Lin ◽  
Yan Bo Li
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Product Quality ◽  
Experimental Research ◽  
Simulation Software ◽  
Blank Holder Force ◽  
Forming Process ◽  
Blank Holder ◽  
Wrought Aluminum

Experimental research on stamping of wrought aluminum alloy has been an important issue at home and abroad. In this paper, taking stamping of aluminum alloy hemispherical components for example, the effects of blank holder force (BHF) on stamping forming process of aluminum alloy are explored by methods of experiments and numerical simulation. Through experiments, the forming laws of hemispherical components are found out. The research shows that the BHF has significant effects on the quality of stamping components and reasonable BHF can greatly improve the formability of hemispherical components. Additionally, by applying simulation software in stamping, the development circle of product and its moulds can be shortened, and product quality and its competitiveness in the market can be improved.

Numerical Simulation of Cylinder Part Based on Dynaform

2012 ◽  
Vol 184-185 ◽  
pp. 337-340
Author(s):  
Ze Hao Hu ◽  
Juan Liu ◽  
Nan Wang
Keyword(s):  
Numerical Simulation ◽  
Experimental Method ◽  
Blank Holder Force ◽  
Forming Process ◽  
Blank Holder

The forming process of a typical cylinder part is simulated by the platform of Dynaform. The influence of blank holder force (BHF), punching speed and clearance between punch and die on the quality of forming part is assessed by the orthogonal experimental method. The value of BHF of 20KN, punching speed of 2000mm/s and clearance between punch and die of 1.1mm which are the optimized parameters value are obtained.

Numerical Simulation Research on Springback Controlling Methods of Aluminum Alloy Panel during Hydroforming

2016 ◽  
Vol 851 ◽  
pp. 163-167
Author(s):  
Dong Yan Lin ◽  
Yi Li
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Process Parameters ◽  
Orthogonal Experiment ◽  
Blank Holder Force ◽  
Scoring Method ◽  
Simulation Research ◽  
Blank Holder ◽  
Hydroforming Process

The hydroforming process of the aluminum alloy panel was simulated by the software DYNAFORM. The effects of process parameters (blank holder force, depth of panel and height of draw bead) on springback of the aluminum alloy were investigated. The max springback of the panel was analyzed by weighted scoring method. Then the process parameters were synthetically optimized for the max positive and negative springback. The results showed that the height of draw bead affects obviously the comprehensive springback of the panel. The optimization of the process parameters obtained by the orthogonal experiment can effectively reduce the max springback of the panel.

Numerical Simulation and Parameter Optimization on Forming Process of Automobile Torque Box

2014 ◽  
Vol 722 ◽  
pp. 140-146
Author(s):  
Wen Juan Zhang ◽  
Long Wu ◽  
Gang Chen
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Parameter Optimization ◽  
Process Parameters ◽  
Fem Simulation ◽  
Simulation Software ◽  
Drawing Process ◽  
Forming Process ◽  
Element Simulation

In this paper the drawing process of Box-torque was simulated by Dynaform, which is FEM simulation software. The process parameters, which affected the quality of forming, were optimized by finite element simulation. The emphasis was focus on the optimization of draw-bead and BHF and data were summarized from the optimization graphs. In this simulation, lengthways draw-bead was set on the technical face for reducing or eliminating wrinkle. It was innovation difference from the usual that the draw-bead was set on binder. Finally the correctness of simulation was approved by comparing the optimization of simulation with the data of experimentation.

Numerical simulation of the effects of the space-variant blank-holder force and geometrical variables in the deep-drawing process

2005 ◽  
Vol 40 (4) ◽  
pp. 375-384
Author(s):  
L Wang ◽  
T. C Lee
Keyword(s):  
Complex Shape ◽  
Geometrical Parameters ◽  
Blank Holder Force ◽  
Minor Strain ◽  
Forming Process ◽  
Blank Holder ◽  
Common Problems ◽  
Blank Size ◽  
Space Variant

The increase in quality requirements for the formed products makes it desirable to find an effective way of controlling the process to achieve complex shape products without defects. It has been proven by many researchers that the space-variant blank-holder force can improve the quality of forming to achieve a targeted shape product (no wrinkling, a high drawing depth, less variation in thickness, etc.). In the forming process, the most common problems, tearing and wrinkling, generally result from the strain condition. In this paper the effect on the strain path with various types of space-variant blank-holder force and other geometrical parameters, such as the fillet radius, the blank size, and the clearance between the die and the punch, were compared and analysed. The results showed that the space-variant blank-holder force and some geometrical parameters affect the strain distribution to various extents during the forming process. The parameters influence the negative minor strain much more than the maximum major strain.

Effect of Die Radius and BHF on Formability of the Corner of Box-Shaped Parts in Deep Drawing Processes

2012 ◽  
Vol 490-495 ◽  
pp. 2071-2075
Author(s):  
Kang Chen ◽  
Cheng Yun Peng ◽  
Bao Bao Li ◽  
Hui Liu
Keyword(s):  
Numerical Simulation ◽  
Deep Drawing ◽  
Simulation Software ◽  
Forming Limit ◽  
Blank Holder Force ◽  
Upward Trend ◽  
Blank Holder ◽  
Constant Size ◽  
Dislocation Movement ◽  
Radius Size

Formability of the corner in the deep drawing of box-shaped parts was studied. The forming of box-shaped parts was simulated through numerical simulation software DYNAFORM from the different die radius size of shoulders and corners, the different BHF of straight and curved edges and different materials, etc.. The results shows that, the forming limit height of box-shaped parts increases with the larger the die radius of shoulders and corners, and forming limit height of SS304 in the materials studied is the highest, because it has larger yield strength; If the BHF of straight and curved edges has the constant size, the forming limit height of box-shaped parts will be lower when the BHF increases, while forming limit has a clear upward trend as blank holder force increases in the deep drawing processes which accords with the change law of resistance during the dislocation movement.

Investigation on Hole Punching Process with Combined Punch to Improve Surface Quality during the Materials Forming Process

2017 ◽  
Vol 737 ◽  
pp. 77-82
Author(s):  
Pan Pan Yao ◽  
Qiang Wang
Keyword(s):  
Numerical Simulation ◽  
Surface Quality ◽  
Hydraulic Press ◽  
Simulation Software ◽  
The Self ◽  
Improve Quality ◽  
Forming Process ◽  
Medium Thickness ◽  
Punching Process

The present work shows the viability of a combined punch that makes possible to perform a hole punching followed by a hole burnishing in only one operation. The advantage of this combined punch is forming processes in only one process on medium thickness plate. In this work were tested two different configurations of punches which one of them is the conventional punch and another is a new structure of combined punch. The new structure of combined punch is added the step and inclined edge at the cutting edge on the basis of conventional punch. They are made of the same materials that are Cr12MoV. The new structure of combined punch and the conventional punch are studied by using numerical simulation and experimental research in this paper. During the materials forming process of hole punching, the simulation software ANSYS is used to simulate. The YZ32-100 Hydraulic press with nominal and the self-made die sets and the thick of 16mm Q235 sheet metal is selected in this experiment. The analysis of the obtained results showed that the hole surface quality of combined punch is superior to the conventional punch. It is prove that the new structure of combined punch can improve quality of punching.

Research and Analysis of Material Flow Regularity in the Process of Cross Wedge Rolling for Wrought Aluminum Alloy

2011 ◽  
Vol 704-705 ◽  
pp. 172-176
Author(s):  
Pei Feng Zhao ◽  
Cun Cang Han ◽  
Yan Min Zhang ◽  
Ke Xing Song
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Outer Layer ◽  
Material Flow ◽  
Flow Characteristic ◽  
Central Axis ◽  
Compression Stress ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Wrought Aluminum

With widely use of aluminum alloy in the cares and other industry fields and the like, the aluminum alloy workpieces are becoming the important components, such as load bearing and so on, in which it has been gradually paid attention to the formation and the producing roughcast of shaft forging part of aluminum alloy. the process of across wedge rolling for wrought aluminum alloy has gradually taken notice of improving production rate and saving metal in this field because of its advantages and superiorities. It is very necessary to research and analyze the flow regularity and forming characteristic of aluminum alloy. In this paper, the forming process of cross wedge rolling for wrought aluminum alloy is simulated with Deform 6.0 soft. Thus, it is analyzed that features about cross wedge rolling for aluminum alloy and changeable characteristic of stress in the central axis and changeable regular of effective stress in wedging stage and stretching stage . At the same time, it is researched that the flow characteristic of aluminum alloy from outer layer to central axis. The results as following: in the forming process of cross wedge rolling for aluminum alloy, the central portion of workpiece is applied by two pairs of tensile stress and one pair of compression stress. The flowing velocity of aluminum alloy is gradually reducing from outer layer to center portion along workpiece’s axis. Keywords: Cross Wedge Rolling, Wrought Aluminum alloy, Stress, Numerical simulation

Analysis of Numerical Simulation in the Deep Drawing of Box-Shaped Parts Using Variable Blank Holder Force

2011 ◽  
Vol 239-242 ◽  
pp. 2694-2697
Author(s):  
Kang Chen ◽  
Cheng Yun Peng ◽  
Tao Zhou ◽  
Bao Bao Li
Keyword(s):  
Numerical Simulation ◽  
Deep Drawing ◽  
Simulation Software ◽  
Straight Edge ◽  
Forming Limit ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Variable Blank Holder Force ◽  
Shaped Part ◽  
Changes Over Time

Blank holder force of box deep drawing is studied changes with time and displacement by DYNAFORM numerical simulation software. The results shows that, when the straight edge part of the blank holder force is constant, rounded part adopts small blank holder force can significantly improve the forming limit of box deep drawing, but the wrinkle is still evident. If the straight edge and rounded part of the blank holder force changes with time, not only deep drawing limit increase, wrinkles are also significantly reduced, indicating that the forming limit of the box shaped part is more effective on the blank holder force changes over time than with the position variation.

Wrinkling Prediction and Optimization of Sheet Metal Forming Process by Numerical Simulation

2015 ◽  
Vol 818 ◽  
pp. 252-255 ◽  
Author(s):  
Ján Slota ◽  
Marek Šiser
Keyword(s):  
Numerical Simulation ◽  
Material Model ◽  
Mechanical Tests ◽  
Simulation Software ◽  
Forming Process ◽  
Part Geometry ◽  
Nominal Thickness ◽  
430 Stainless Steel ◽  
Metal Forming Process ◽  
Aisi 430

The paper deals with optimization of forming process for AISI 430 stainless steel with nominal thickness 0.4 mm. During forming of sidewall for washing machine drum, some wrinkles remain at the end of forming process in some places. This problem was solved by optimization the geometry of the drawpiece using numerical simulation. During optimization a series of modifications of the part geometry to absolute elimination of wrinkling was performed. On the basis of mechanical tests, the material model was created and imported into the material database of Autoform simulation software.

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