Improvement of Hole Flanging Product Forming Process Using Finite Element Simulation

2010 ◽  
Vol 97-101 ◽  
pp. 344-347 ◽  
Author(s):  
Xue Wen Chen ◽  
Jun Wei Zhao ◽  
Dong Won Jung
Keyword(s):  
Metal Forming ◽  
Cold Forging ◽  
Forming Process ◽  
Forging Process ◽  
Counter Pressure ◽  
Element Simulation ◽  
Metal Forming Process ◽  
Die Set ◽  
Hole Flanging ◽  
Deform 3D

Flanging is a method of sheet metal forming process under combined compressive and tensile conditions using a punch and die to raise closed rims (flanges or collars) on pierced holes. For the flanging product used for the automotive steering part, the thickness of the bottom radius area is very important because of the crack usually occurred during the using process. But during conventional flanging process, the thickness of the rim and the bottom radius area were decreased seriously and make the hole flanging not strong enough to be used. In order to increase the thickness of bottom radius area of the flanging wall, a new method that combines flanging process and cold forging process was proposed in this paper and a special forming die set was designed with a stripper subjected to counter-pressure with an aim to obtain a more substantial flange. FEM software DEFORM 3D was employed to simulate these flanging part forming processes. The results showed the thickness of bottom radius area of the flanging wall was increased and a more substantial flange was obtained.

scholarly journals LOAD PREDICTION ON METAL FORMING PROCESS (FORGING) USING FINITE ELEMENT METHOD.

2020 ◽  
Vol 2 (1) ◽  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Metal Forming ◽  
Weighted Residual Method ◽  
Forming Process ◽  
Residual Method ◽  
Forging Process ◽  
Metal Forming Process ◽  
Metal Blank ◽  
Element Method

Metal forming process is a widely used manufacturing process especially in high volume metal production system. In this paper, the main objective is using Bubnov-Galerkin finite element model to derive the pressure field set up at various cross-sections of a metal blank during a forging process, and the four Lagrange quadratic elements were assembled to represent the various metal blank. The governing equation adopted for this paper is a one-dimensional differential equation describing the pressures exerted on the forging process. During the analysis, the various metal blanks are divided into a finite number of elements and the weighted integral form for each element were formed after applying the Bubnov-Galerkin weighted residual method. A matrix form under certain boundary conditions from the weighted residual method were used to obtain the pressure distribution across the cross-section of the various metal blanks. Finite element results are obtained for a value of a circular disc diameter, thickness, coefficient of friction, principal stress, length, and radius of a circular material. Finite element method and the Exact solution approach are used to achieve and compare both results. Furthermore, the combination of both methods shows that there are potentials for using this approach towards the optimization of metal forming in manufacturing processes and some engineering practices. Keywords: Forging; LaGrange Interpolation Function; Bubnov-Galerkin Weighted Residual Method; Finite Element Method.

Analysis of the Contact Length During Micrometal Forming to Establish Its Efficient Measurement Method

2020 ◽  
Vol 8 (2) ◽  
Author(s):  
L. Rathmann ◽  
F. Vollertsen
Keyword(s):  
Metal Forming ◽  
Measurement Method ◽  
Deformable Body ◽  
Direct Determination ◽  
Contact Length ◽  
Forming Process ◽  
Contact Zones ◽  
Element Simulation ◽  
Metal Forming Process ◽  
Efficient Measurement

Abstract In microsheet metal forming, the lengths of the contact zones between blank and die are important parameters to describe the contact behavior, but they can hardly be detected experimentally. Thus, a finite element simulation enables access to these zones and especially, their length. This length and its development during a metal forming process are analyzed in this work to establish its efficient measurement method. The part at the die called drawing edge is defined as a deformable body with material properties. Since every node of such a body can report pressure, the contact length is the product of the number of n – 1 nodes under contact pressure with the equidistant distance of lE = 1 μm between each node. It is shown, that with this method the direct determination of the contact zones position and length is enabled. Additionally, the simulative results show that the contact length is influenced by the geometrical conditions of the punch and die.

Influence of the Blankholder Force on the Accuracy of the Rectangular Drawn Parts Made from Steel Sheets

2013 ◽  
Vol 371 ◽  
pp. 143-147
Author(s):  
Neculai Nanu ◽  
Gheorghe Brabie ◽  
Maria Bologan
Keyword(s):  
Process Parameters ◽  
Metal Forming ◽  
Anisotropy Coefficient ◽  
Forming Process ◽  
Shape Accuracy ◽  
Steel Sheets ◽  
Element Simulation ◽  
Virtual Reconstruction ◽  
Metal Forming Process ◽  
The One

In the case of sheet metal forming process one of the most important phenomena that affect the dimensional and shape accuracy of the formed parts is the part springback after the tools removing. The springback phenomenon depends, on the one hand by the material mechanical parameters (especially Youngs modulus, anisotropy coefficient, yield stress) and on the other hand by the process parameters and tools geometry. Therefore in order to control the springback for a given material, the influence of the process parameters or tools geometry must be know. The aim of the present paper is to investigate the effect of blankholder force (as process parameter) on the springback parameters in the case of rectangular parts made from steel sheets. The investigations were made both experimentally and by finite element simulation. The springback parameters of the obtained parts were determined by using the ATOS system and ATOS software that allows the virtual reconstruction of the part shape in order to measure the springback parameters. Both experimental and simulation tests shown that the use of a high value of blankholder force leads to the increase of the drawn part accuracy.

Hollow Lateral Extrusion of Tubular Billets – Further Development of the Cold Forging Process

2015 ◽  
Vol 794 ◽  
pp. 160-165 ◽  
Author(s):  
Jonas Wälder ◽  
Mathias Liewald
Keyword(s):  
Structural Design ◽  
Metal Forming ◽  
Room Temperature ◽  
Cold Forging ◽  
Forming Process ◽  
Forging Process ◽  
Lateral Extrusion ◽  
Funded Project ◽  
Hollow Billets ◽  
Further Development

Light weight engineering in structural design and use of lighter materials are becoming increasingly important in bulk metal forming. Results gained by a DGF funded project which will be introduced in the following, concerning novel advancements of hollow lateral extrusion. Paper exhibits further development of this process, so cold forged components having undercuts without using a lateral tool plane easily can be manufactured. Thereby, the focus of attention is on the tool design as well as on the analysis of the unmodified forming process. Therefore, experimentally investigations have been carried out, failures on components are analyzed and process limitations of an experimental setup for cold forging of hollow billets at room temperature are illustrated.

scholarly journals Laser Welding of High-strength Aluminium Alloys for the Sheet Metal Forming Process

Procedia CIRP ◽  
2014 ◽  
Vol 18 ◽  
pp. 203-208 ◽  
Author(s):  
J. Enz ◽  
S. Riekehr ◽  
V. Ventzke ◽  
N. Sotirov ◽  
N. Kashaev
Keyword(s):  
Laser Welding ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Aluminium Alloys ◽  
High Strength ◽  
Forming Process ◽  
Metal Forming Process
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