Sheet Metal Forming Process Design Rules Development

2011 ◽  
Vol 473 ◽  
pp. 765-772
Author(s):  
Antonio del Prete ◽  
Gabriele Papadia ◽  
Teresa Primo
Keyword(s):  
Process Design ◽  
Process Variable ◽  
Complex Problem ◽  
Industrial Test ◽  
Thickness Ratio ◽  
Die Design ◽  
Design Development ◽  
Forming Process ◽  
Element Analysis ◽  
Constitutive Material

Finite element analysis (FEA) is a powerful tool to evaluate the formability of stamping parts during process and die design development procedures. However, in order to achieve good product quality and process reliability, FEA application has to be performed many times exploring different process parameters combinations. Meanwhile, it is very difficult to perform an exhaustive process design definition when many parameters play a fundamental role to define such a complex problem. So, under the needs of reduction in: design time, development cost and parts weight, there is an urgent need to develop and apply more efficient methods in order to improve the current design procedures. For a generic component it is clear how its shape, among several parameters, has a direct influence on its feasibility. Starting from this assumption, the authors have developed a new approach grouping components upon their shapes analyzing component formability within a given “component family”. Nowadays, it exists only a process designer “sensitivity” that produces a ranking upon shape/feasibility ratio. Having as reference industrial test cases, the authors have defined appropriate shape parameters in order to have dimensionless coefficients representative for the given geometries. In particular, the components have been classified using a parameters set defining similarity families: related to geometrical aspects and to constitutive material. From the geometrical point of view the following parameters have been defined: family name, shape factor, punch radius-thickness ratio, die radius-thickness ratio, while for the constitutive material a code has been defined. FEA has been extensively used in order to: define, investigate and validate each shape parameter with a proper comparison to the macro feasibility of the chosen component geometry. The feasibility configuration definition, for a given shape, has been made through an appropriate study of the influence of each process variable on the properly process performances.

Semi-Enclosed Cold Forging Process Analysis and Progressive Die Design of CPU Fin

2008 ◽  
Vol 575-578 ◽  
pp. 174-179
Author(s):  
Juan Hua Su ◽  
Feng Zhang Ren ◽  
Lei Wang
Keyword(s):  
Production Efficiency ◽  
High Efficiency ◽  
Process Analysis ◽  
Die Design ◽  
Cold Forging ◽  
Forming Process ◽  
Element Analysis ◽  
Whole Process ◽  
Progressive Dies ◽  
Transfer Unit

This paper analyzes the forming process methods of fin used in CPU chip to emit heat. The whole process is blanking, the first forging forming, the second forging (sizing), and trimming. The chamfer design of CPU fin blank is simulated by finite element analysis. The optimized chamfer 1.6 mm is available. Semi-enclosed cold forging of progressive dies is put forward. The newly designed transfer unit is applied, which unifies the merit of high efficiency of the progressive dies and the high material-using ratio of the project die. Quick disassembly structure is designed and pins are used as quick disassembly pins by means of ball bearing bushing. The unique processing of the shearing scrap structure is adopted when designing the inverted trimming dies. Compared with the traditional die, the mechanization and electrization are realized to increase the production efficiency and get highly precise CPU fin.

scholarly journals Flexible Die Design and Springback Compensation Based on Modified Displacement Adjustment Method

2014 ◽  
Vol 6 ◽  
pp. 131253 ◽  
Author(s):  
Young-Ho Seo ◽  
Ji-Woo Park ◽  
Woo-Jin Song ◽  
Beom-Soo Kang ◽  
Jeong Kim
Keyword(s):  
Closed Loop ◽  
Three Dimensional ◽  
Loop System ◽  
Die Design ◽  
Manufacturing Cost ◽  
Closed Loop System ◽  
Forming Process ◽  
Element Analysis ◽  
Springback Compensation ◽  
Flexible Die

Springback in metal forming process often results in undesirable shape changes in formed parts and leads to deterioration in product quality. Even though springback can be predicted and compensated for through the theories or methodologies established thus far, an increase in manufacturing cost accompanied by a change in die shape is inevitable. In the present paper, it is suggested that the cost accompanied with springback compensation can be minimized while allowing the processing of various three-dimensional curved surfaces by using a flexible die composed of multiple punches. With the die being very flexible, the iterative trial-and-error method can be readily applied to compensate for the springback. Thus, repeated designing and redesigning of solid or matched dies can be avoided, effectively saving considerable time. Only some adjustments of punch height are required. Detailed designs of the flexible die as well as two core algorithms to control the respective punch heights are described in this paper. In addition, a closed-loop system for the springback compensation using the flexible die is proposed. The amount of springback was simulated by a finite element analysis and the modified displacement adjustment (DA) method as the springback compensation model was used in the closed-loop system. This system was applied to a two-dimensional quadratic shape problem, and its robustness was verified by an experiment.

Sheet Metals Forming Die Design Using Finite Element Analysis and the Taguchi Method

2014 ◽  
Vol 621 ◽  
pp. 195-201
Author(s):  
Surangsee Dechjarern ◽  
Maitri Kamonrattanapisut
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Friction Coefficient ◽  
Taguchi Method ◽  
Finite Element Model ◽  
Sheet Metal ◽  
Element Model ◽  
Die Design ◽  
Forming Process ◽  
Element Analysis

Sheet metal deep-draw die is primarily constructed with draw bead, which is then modified based on trial and error to obtain a successful forming without splitting. This work aims at a robust design of forming die using numerical analysis and the Taguchi method. A three dimensional elastoplastic finite element model of a sheet metal forming process of SPCEN steel has been successfully developed using the material flow stress obtained from the modified Erichsen cup test. The model was validated with the actual forming experiment and the results agreed well. The influence of draw bead parameters on splitting and thinning distributions were examined using the Taguchi method. Four parameters, namely the friction coefficient, draw bead height, radius and shoulder radius were investigated. The Taguchi main effect analysis and ANOVA results show that the height and shoulder radius of the draw bead are the most important factor influencing the thinning distribution. Applying the Taguchi method and using the minimum thinning percentage as the design criteria, the optimum die design was identified as height, radius, shoulder radius and the friction coefficient of 4, 8, 8 mm and 0.125 respectively. The verified finite element model using the optimum die design was conducted. The predicted Taguchi response was within 5.9% from finite element analysis prediction. The improvement in the reduction of thinning percentage was 22.35%.

Experimental Investigations and Automatic Numerical Optimization of a Bulk Metal Forming Process to Avoid Forging Folds

2015 ◽  
Vol 651-653 ◽  
pp. 305-310
Author(s):  
Bernd Arno Behrens ◽  
Sonda Moakhar Bouguecha ◽  
Milan Vucetic ◽  
Anas Bouguecha ◽  
Mohammad Kazhai
Keyword(s):  
Process Parameters ◽  
Process Design ◽  
Numerical Optimization ◽  
Experimental Investigations ◽  
Forming Process ◽  
Element Analysis ◽  
Complex Processes ◽  
Metal Forming Process ◽  
Fold Formation ◽  
Indispensable Tool

The detection of process failures in earlier design stages is essential for preventing high additional costs and a loss of time. Here, the finite element analysis (FEA) is an inherent part of the process design. This work represents numerical and experimental investigations, which were carried out in order to identify factors that influence the fold formation in an upsetting process of hollow parts, i.e. different forging velocities, different materials or the friction. The experimental results were compared with the numerical simulations. Based on these investigations, an automatic optimization model was created, which is the focus of this work. It allows varying and optimizing the experimentally determined process parameters, influencing the fold formation, automatically with the aim to produce a workpiece free of folds. For this purpose the commercial Software-System Forge (Transvalor) was used. The results of this work provide basic information for the development of complex processes. It can be shown that the automatic numerical optimization is an indispensable tool for the process design. It helps determining optimal process parameters individually and avoiding extensive trial and error investigations and hence a loss of time and costs.

Concurrent Engineering in the Application of Automobile Covering Parts Mould Development

2013 ◽  
Vol 397-400 ◽  
pp. 607-610
Author(s):  
Min Fu ◽  
Chui You Kong ◽  
Bing Bing Wang ◽  
Ming Hang Chen
Keyword(s):  
Concurrent Engineering ◽  
Die Design ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Simulation ◽  
Mould Surface ◽  
Development Life Cycle ◽  
The Finite Element Analysis ◽  
Mould Design ◽  
Repeated Test

Describe an advanced design and manufacturing technology Concurrent Engineering (CE) and give the automobile covering parts mould development flow basing on concurrent engineering. It tries to consider initially all factors of the mould development life cycle. Take an automobile covering part for example. Basing on the finite element analysis software AUTOFORM, do die design and forming simulation. According to the result of simulation, designer can predict the defect of forming and timely modify the forming process. So in stage of process design taking into account the blank forming, this kind of concurrent design of the mould surface can be directly used to mould design, also won't return after the mold design to modify the die-face design process. So on account of concurrent engineering, it can reduce the changes of automobile covering parts mould design and the number of repeated test, improve quality, reduce cost, and shorten the cycle of mould development.

scholarly journals Die Design for Extrusion Process of Titanium Seamless Tube Using Finite Element Analysis

Metals ◽  
2021 ◽  
Vol 11 (9) ◽  
pp. 1338
Author(s):  
Byung-Jin Choi ◽  
In Yong Moon ◽  
Young-Seok Oh ◽  
Seong-Hoon Kang ◽  
Se-Jong Kim ◽  
...  
Keyword(s):  
Finite Element ◽  
Extrusion Process ◽  
Maximum Principal Stress ◽  
Die Design ◽  
Von Mises Stress ◽  
Design Parameters ◽  
Forming Process ◽  
Element Analysis ◽  
Corner Radius ◽  
Von Mises

In this paper, the extrusion process of titanium seamless tubes was studied using several finite element (FE) analyses. First, the finite element result was compared with experimental extrusion data acquired to validate the current analysis. Then, the effect of design parameters of the die shape was numerically analyzed using commercial FE software, Forge NxT, for the metal forming process. Elastic FE analyses were also conducted for dies to analyze the maximum principal stress that affects the early fracture of dies during the extrusion process and the maximum von Mises stress that causes the severe deformation of dies. Consequently, the effect of the corner radius at the exit and land length on the extrusion load and die stress is negligible compared to that of the corner radius at the entrance and die angle. Finally, we suggested a die angle of 60° and a corner radius at the die entrance between 10 and 15 mm as an optimal design for the current extrusion process.

Research on the Metal Forming Process of the Muffler Tube Using Finite Element Method

2008 ◽  
Vol 385-387 ◽  
pp. 841-844
Author(s):  
Kyu Taek Han ◽  
Yi Jiong Jin
Keyword(s):  
Finite Element ◽  
Process Design ◽  
Metal Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Punch Radius ◽  
Metal Forming Process ◽  
Fracture Theory ◽  
Simulation Results ◽  
Fourth Component

A muffler is an important part used to reduce noise and to purify exhaust gas in cars and heavy equipments. Recently there has been a growing interest in the designing and manufacturing the muffler tube due to the strict environmental regulations. The technique of perforating on the muffler tube has been largely affected by the shear clearance. And considering the concentration of the force around the punch edge, it is essential to reduced it through the punch radius. In this research, finite element analysis has been carried out to predict optimal forming conditions of the muffler tube using DEFORMTM-3D. In analysis, using one-fourth component of the punch and die, metal forming process is simulated and Cockcroft-Latham ductile fracture theory is used. According to the simulation results, when the shear clearance is 0.04mm, the punch radius is 0.05mm and the value of plate holder force is 250KN, the relation of load-stroke for punch is optimized. Also the burr is minimized and optimal shear section is obtained. The simulation results are reflected to the forming process design for the muffler tube.

A Knowledge-Based Engineering Method to Integrate Metal Forming Process Design and Simulation

1994 ◽  
Author(s):  
Tom Robertson ◽  
Biren Prasad ◽  
Ravi Duggirala
Keyword(s):  
Process Design ◽  
Metal Forming ◽  
Computer Aided Design ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Simulation ◽  
Knowledge Based ◽  
Metal Forming Process ◽  
Knowledge Based Engineering ◽  
Integrate Design

Abstract The integration of Computer Aided Design (CAD) and Finite Element Analysis (FEA) tools is an important consideration in metal forming design. Traditionally, engineering functions such as classical analysis, FEA, CAD, etc. are performed separately. The emergence of knowledge-based engineering (KBE) tools and its language-based structure provides a basis to integrate design functions. This paper presents a KBE system which effectively integrates metal forming process design and FEA analysis by automating the pre-processing required for metal forming simulation for two dimensional problems. The method will be applicable to 3D problems as FEA technology improves.

Laser Forming of Varying Thickness Plate—Part II: Process Synthesis

2005 ◽  
Vol 128 (3) ◽  
pp. 642-650 ◽  
Author(s):  
Peng Cheng ◽  
Yajun Fan ◽  
Jie Zhang ◽  
Y. Lawrence Yao ◽  
David P. Mika ◽  
...  
Keyword(s):  
Plane Strain ◽  
Process Design ◽  
Laser Scanning ◽  
Plate Thickness ◽  
Laser Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Varying Thickness ◽  
Bending Strain ◽  
Finite Element Analysis Simulation

Laser forming (LF) is a non-traditional forming process that does not require hard tooling or external forces and, hence, may dramatically increase process flexibility and reduce the cost of forming. While extensive progress has been made in analyzing and predicting the deformation given a set of process parameters, few attempts have been made to determine the laser scanning paths and laser heat conditions given a desired shape. This paper presents a strain-based strategy for laser forming process design for thin plates with varying thickness, which is utilized in determining the scanning paths and the proper heating conditions. For varying thickness plates, both the in-plane membrane strain and the bending strain need to be accounted for in process design. Compared with uniform thickness plate, the required bending strain varies with not only the shape curvature but also with the plate thickness. The scanning paths are determined by considering the different weight of bending strain and in-plane strain. A thickness-dependent database is established by LF finite element analysis simulation, and the heating conditions are determined by matching the ratio of bending strain to in-plane strain between the required values and the laser forming values found in the database. The approach is validated by numerical simulation and experiments using several typical shapes.

Measurement and Calculation of Elastic Properties in Low Carbon Steel Sheet

2005 ◽  
Vol 495-497 ◽  
pp. 1591-1596 ◽  
Author(s):  
Vladimir Luzin ◽  
S. Banovic ◽  
Thomas Gnäupel-Herold ◽  
Henry Prask ◽  
R.E. Ricker
Keyword(s):  
Carbon Steel ◽  
Elastic Property ◽  
Elastic Properties ◽  
Steel Sheet ◽  
Low Carbon Steel ◽  
Low Carbon ◽  
Forming Process ◽  
Element Analysis ◽  
Wide Range ◽  
Carbon Steel Sheet

Low carbon steel (usually in sheet form) has found a wide range of applications in industry due to its high formability. The inner and outer panels of a car body are good examples of such an implementation. While low carbon steel has been used in this application for many decades, a reliable predictive capability of the forming process and “springback” has still not been achieved. NIST has been involved in addressing this and other formability problems for several years. In this paper, texture produced by the in-plane straining and its relationship to springback is reported. Low carbon steel sheet was examined in the as-received condition and after balanced biaxial straining to 25%. This was performed using the Marciniak in-plane stretching test. Both experimental measurements and numerical calculations have been utilized to evaluate anisotropy and evolution of the elastic properties during forming. We employ several techniques for elastic property measurements (dynamic mechanical analysis, static four point bending, mechanical resonance frequency measurements), and several calculation schemes (orientation distribution function averaging, finite element analysis) which are based on texture measurements (neutron diffraction, electron back scattering diffraction). The following objectives are pursued: a) To test a range of different experimental techniques for elastic property measurements in sheet metals; b) To validate numerical calculation methods of the elastic properties by experiments; c) To evaluate elastic property changes (and texture development) during biaxial straining. On the basis of the investigation, recommendations are made for the evaluation of elastic properties in textured sheet metal.

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