Die Design in Fine-Piercing Process by Chamfering Cutting Edge

2010 ◽  
Vol 443 ◽  
pp. 219-224 ◽  
Author(s):  
Suthep Yiemchaiyaphum ◽  
Masahiko Jin ◽  
Sutasn Thipprakmas
Keyword(s):  
Process Parameters ◽  
Flow Analysis ◽  
Fem Simulation ◽  
Material Flow Analysis ◽  
Cutting Edge ◽  
Die Design ◽  
The Finite Element Method ◽  
Sheet Metal Parts ◽  
Secondary Operations ◽  
Die Roll

The hole quality on sheet metal parts is directly dependent on the die design and process parameters. In conventional piercing process, the secondary operations such as shaving, reaming and grinding are needed for manufacturing the precise-dimensioned holed parts without any cracks, resulting in the increase of both production time and costs. The fine-piercing process, referenced to the fine-blanking principle, is used to produce the precise-dimensioned holed parts with smooth-cut surfaces over the whole material thickness in a single operation. However, it is difficult to achieve the suitable die design and process parameters for meeting the part requirements. In this study, the die design by chamfering punch cutting edge was investigated on both the experiments and the finite-element method (FEM). The results were compared with the results obtained when the conventional die design with the punch cutting-edge radius was used. The FEM-simulation results showed the amount of die-roll, smooth-cut surface, and cracks agreed well with the experimental results. The results showed that an application of punch cutting-edge chamfer results in a superior fine-pierced hole surface could be achieved. Furthermore, the mechanism and effects of the punch cutting-edge chamfer have been theoretically clarified on basis of the material-flow analysis and stress distribution.

Application of Back-Up Ring in Fine-Blanking Process

2010 ◽  
Vol 443 ◽  
pp. 140-145 ◽  
Author(s):  
Suthep Yiemchaiyaphum ◽  
Masahiko Jin ◽  
Sutasn Thipprakmas
Keyword(s):  
Flow Analysis ◽  
Fem Simulation ◽  
Material Flow Analysis ◽  
The Finite Element Method ◽  
Fine Blanking ◽  
Die Roll ◽  
Blanking Process ◽  
Cut Surface ◽  
Good Agreement

Considering the advantages of the fine-blanking process, the smooth-cut surface without further operation could be fabricated. However, one of the major problems of the fine-blanking is the occurrence of the die-roll formation. This problem is the main factor which affects the quality of the fine-blanked parts. In this study, to reduce the amount of die-roll formation, the application of back-up ring was proposed. The finite element method (FEM) was used to investigate the effects of back-up ring. In addition, the effects of bridge width were also investigated. The FEM simulation results illustrated that the mechanism of back-up ring and the effects of bridge width could be theoretically clarified base on the material flow analysis. The FEM simulation and experimental results showed the good agreement with each other. Therefore, the application of back-up ring could reduce the amount of die-roll formation on the fine-blanked parts. In this study, the amount of die-roll formation increased as the bridge width increase and it was constant at the bridge width of over 15 mm.

FEM Simulation of the Whole Circle of Aluminum Hot Extrusion Using Circular Dies With Different Extrusion Angle

2006 ◽  
Author(s):  
A. Lontos ◽  
K.-D. Bouzakis ◽  
G. Demosthenous ◽  
A. Baldoukas
Keyword(s):  
Product Quality ◽  
Process Parameters ◽  
Surface Condition ◽  
Fem Simulation ◽  
Hot Extrusion ◽  
Die Design ◽  
Work Piece ◽  
Billet Temperature ◽  
Extrusion Die ◽  
Ram Speed

On of the most typical forming processes used for the production of long, straight semi-finished products in the form of various section geometries is extrusion. Hot extrusion is a thermo-mechanical process whish involves complicated interactions between process parameters, tooling and deforming material /1,2/. In the present paper, FEM simulation is performed in the aluminum extrusion using circular dies with different geometries in order to extract quantitative simulating results regarding various forming parameters. Most specifically the parameters that are investigated are the die design-geometry, the process parameters (i.e. ram speed, container temperature, billet temperature) and the product quality (i.e. extruded shape, surface condition). The finite element modeling is based on 3D simulation tools using the DEFORM 3D software /3–5/. The used work piece is the aluminum AA6061 in cylindrical form with a diameter of 14 mm. The used material for the extrusion die is the hot work steel AISI H13. The geometry of the die is circular with a variation in die angle. The container and the billet temperature will vary from 450 to 550 degrees, and the mandrel (ram) speed will be at the range of 2 mm/sec. On the basis of simulating results such as pressure distribution on the extrusion die, effective stresses on the billet and product quality, new and improve die geometry will be introduced. Although the simulation problem is an axisymmetric one the authors decide to proceed with 3D FEM simulation in order to examine and verify the 3D simulating results. This paper is the first part of a further research project in which more complicated die geometries will be used as simulating and experimental specimens. In addition to simulating results, experimental results will be presented in the next few months.

Application of FEM Simulation and Abductive Network to Predict the Springback of U-Shaped Bending Process with Counter Force

2012 ◽  
Vol 579 ◽  
pp. 32-41
Author(s):  
Tung Sheng Yang ◽  
Jen Chuan Yeh ◽  
Sheng Yi Chang
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
Fem Simulation ◽  
Data Sets ◽  
The Finite Element Method ◽  
Blank Holder Force ◽  
Element Analysis ◽  
Blank Holder ◽  
Bending Process ◽  
Abductive Network

This study applies the finite element method (FEM) in con-junction with an abductive network to predict springback’s angle during the U-shaped bending process with counter force. To verify the prediction of FEM simulation for springback, the experimental data are compared with the results of current simulation. Bending force, effective stress distribution and springback are investigated for different process parameters, such as profile radius of die, blank holder force and counter force of U-shaped bending process, by finite element analysis. The abductive network is then utilized to synthesize the data sets obtained from numerical simulations. Finally, prediction model is established for predicting springback’s angle under a suitable range of process parameters.

The Model for Coupled Simulation of Thin Profile Extrusion

2012 ◽  
Vol 504-506 ◽  
pp. 505-510 ◽  
Author(s):  
Nikolay Biba ◽  
Sergei Stebunov ◽  
Andrey Lishny
Keyword(s):  
Material Flow ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
Die Design ◽  
Production Environment ◽  
Complex Shapes ◽  
Die Stress ◽  
Die Materials ◽  
High Elongation ◽  
Flow Through

The paper presents the latest development of the numerical model for extrusion of industrial profiles having complex shapes. The model provides the material flow analysis coupled with mechanical and thermal problems in the tooling set. The simulation predicts possible shape deterioration due to uneven material flow through the bearing zone and helps to equalise it by means of optimisation of the bearing design, chamber and feeding channels. The locations of welding zones in the die are clearly predicted. It allows to modify the die design for better welding conditions and to provide optimal location of welding seams in the product. Die stress analysis shows the ways to extend the tool life by means of reducing of fatigue failure and selecting proper die materials as well as to correct the influence of the die deformation on the material flow. The described model is implemented in an especially dedicated program QForm-Extrusion that effectively simulates the extrusion of hollow and solid profiles with very high elongation ratios. The experimental verification of the model is illustrated by model and industrial experiments as well as by series of case studies performed in production environment.

Reciprocating Shaving Approach to Eliminate Crack and Burr Formations in Pressed Parts

2010 ◽  
Vol 443 ◽  
pp. 201-206 ◽  
Author(s):  
Sutasn Thipprakmas ◽  
Wiriyakorn Phanitwong ◽  
Mutjarin Chinwithee ◽  
Thanaporn Morkprom
Keyword(s):  
Process Parameters ◽  
Metal Cutting ◽  
Fem Simulation ◽  
The Finite Element Method ◽  
Working Process ◽  
Cutting Operation ◽  
The Cost ◽  
Sheet Metal Cutting ◽  
Cut Surface ◽  
Good Agreement

Burrs are unwanted materials remaining not only after the machining operation but also after the sheet metal cutting operation. Burr formations decrease the part accuracy and increase the cost for the deburring operation. In this study, the reciprocating shaving process was proposed to eliminate crack and burr formations in the pressed parts. The finite element method (FEM) was used as a tool to investigate the possibility of this process and its working process parameters as well. The FEM simulation results showed the effects of clearance in shearing operation, shaving allowance, and half-shaving direction on the shaved surface. These results were validated by laboratory experiments, and they showed a good agreement with each other. The FEM simulation could be used as a tool for prediction of the cut surface in the reciprocating shaving process. The results revealed that the reciprocating shaving process could be applied for eliminating crack and burr formations in pressed parts using suitable working process parameters.

scholarly journals Life Cycle Assessment and Material Flow Analysis: Two Under-Utilized Tools for Informing E-Waste Management

2021 ◽  
Vol 13 (14) ◽  
pp. 7939
Author(s):  
Sohani Vihanga Withanage ◽  
Komal Habib
Keyword(s):  
Life Cycle Assessment ◽  
Life Cycle ◽  
Material Flow ◽  
Keyword Search ◽  
Technological Development ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
Civil Society Organizations ◽  
The Past ◽  
Depth Analysis

The unprecedented technological development and economic growth over the past two decades has resulted in streams of rapidly growing electronic waste (e-waste) around the world. As the potential source of secondary raw materials including precious and critical materials, e-waste has recently gained significant attention across the board, ranging from governments and industry, to academia and civil society organizations. This paper aims to provide a comprehensive review of the last decade of e-waste literature followed by an in-depth analysis of the application of material flow analysis (MFA) and life cycle assessment (LCA), i.e., two less commonly used strategic tools to guide the relevant stakeholders in efficient management of e-waste. Through a keyword search on two main online search databases, Scopus and Web of Science, 1835 peer-reviewed publications were selected and subjected to a bibliographic network analysis to identify and visualize major research themes across the selected literature. The selected 1835 studies were classified into ten different categories based on research area, such as environmental and human health impacts, recycling and recovery technologies, associated social aspects, etc. With this selected literature in mind, the review process revealed the two least explored research areas over the past decade: MFA and LCA with 33 and 31 studies, respectively. A further in-depth analysis was conducted for these two areas regarding their application to various systems with numerous scopes and different stages of e-waste life cycle. The study provides a detailed discussion regarding their applicability, and highlights challenges and opportunities for further research.

Dynamic material flow analysis of natural graphite in China for 2001-2018

2021 ◽  
Vol 173 ◽  
pp. 105732
Author(s):  
Xue Rui ◽  
Yong Geng ◽  
Xin Sun ◽  
Han Hao ◽  
Shijiang Xiao
Keyword(s):  
Material Flow ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
Natural Graphite

Dynamics of Regional Recycling Economy Development Based on Material Flow Analysis: A Case Study in Shandong Province

2011 ◽  
Vol 347-353 ◽  
pp. 2961-2966
Author(s):  
Dian Ming Geng ◽  
Jia Xiang Liu
Keyword(s):  
Water Supply ◽  
Circular Economy ◽  
Material Flow ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
Shandong Province ◽  
Utilization Efficiency ◽  
Recycling Economy ◽  
Material Input ◽  
Inputs And Outputs

In order to study the development of regional recycling economy, the material inputs and outputs of the eco-economic system in Shandong Province during the period from 1996 to 2009 were systematically analyzed by the material flow analysis(MFA). The results show that, (1)excluding water, material inputs and outputs rose persistently, but both were lower than the rate of GDP growth. (2)Water supply had a turning point in 2003, from 25.239 billion tons down to 21.934 billion tons, followed by the total annual water supply has been maintained at 220 million tons. At the same time the amount of wastewater emissions is increasing, especially domestic wastewater emissions had faster growth and that increased pressure on the regional water environment;(3) Steady increase in material input intensity, material output intensity presented a first increased and then decreased trend, that showed since Shandong Province proposed the strategic planning to develop circular economy, the development of regional circular economy have improved the material utilization efficiency and made a material reduction in output in the case of material input growth achieved. The rapid increase of material input and output efficiency further illustrated the efficiency of resource comprehensive utilization and waste output have been significantly improved.

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