Sensitivity Analysis of Process Parameters in the Drawing and Ironing Processes

2013 ◽  
Vol 554-557 ◽  
pp. 2256-2265 ◽  
Author(s):  
Vasco M. Simões ◽  
Jeremy Coër ◽  
Hervé Laurent ◽  
M.C. Oliveira ◽  
J. Luís Alves ◽  
...  
Keyword(s):  
Process Parameters ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
Experimental Tests ◽  
Contact Forces ◽  
Outer Diameter ◽  
Forming Process ◽  
Punch Force ◽  
Inner Radius ◽  
Cylindrical Cup

Deep drawing is one of the most important operations used in sheet metal forming. Within this, forming of cylindrical cup is one of the most widely studied deep drawing processes since it allows analysing the effect of different process parameters in phenomena such as earing, springback and ironing. In fact, during the deep drawing of a cylindrical cup the blank thickness gradually increases as the blank outer diameter is reduced to the die inner diameter, resulting in a thickness increase from a point near the bottom radius until the maximum value at the top of the cup. Therefore, if the gap between the punch and the die is not sufficiently large to allow the blank material to flow, ironing of the cup wall will occur. The ironing process typically imposes high contact forces, normal to the surface of the punch and the die, which can lead to the occurrence of galling, particularly for aluminium alloys. In this work an experimental device, adopted in previous studies, was used to analyse the influence of the lubricant conditions in the deep drawing of a cylindrical cup. The study considers an AA5754-O aluminium alloy blank with a diameter of 60 mm, which is fully deep drawn with a 33 mm diameter punch. Due to the forming conditions, the cup is deep drawn and ironing of the cup wall also occurs. The experimental tests were performed considering different amounts of lubricant in the blank surfaces in the contact with the die and with the blank-holder in order to better understand the influence of these tools on the process. The experimental study was complemented with numerical simulations, exploring the conditions induced by the ironing operation, quite challenging for the numerical simulation of the process using the finite element method. Besides the influence of the contact with friction conditions in the forming process (i.e. punch force evolution, thickness distribution along the cup wall and contact pressure), the influence of the die shoulder and inner radius were also analysed.

Thickness of Magnesium Alloy Cylindrical Cup in Pressure-Lubricating Deep Drawing

2012 ◽  
Vol 189 ◽  
pp. 147-151
Author(s):  
Xian Chang Mao ◽  
Hai Yan Lin
Keyword(s):  
Magnesium Alloy ◽  
Wall Thickness ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
Blank Holder Force ◽  
Technological Parameters ◽  
Forming Process ◽  
Blank Holder ◽  
Deformation Behaviors ◽  
Cylindrical Cup

Forming process of AZ31B magnesium alloy cup parts in pressure-lubricating deep drawing was simulated by Dynaform at room temperature. The technological parameters which influence the wall thickness difference of cup parts were investigated in this paper, including internal pressure, blank holder force and punch corner radius, etc. Compared with the deformation behaviors of magnesium alloy in mechanical deep drawing and pressure-lubricating deep drawing, the wall thickness distribution of cup parts was discussed. The result shows that preferable deformation behaviors can be obtained in pressure-lubricating deep drawing when adopted adaptive technological parameters.

Study on the Forming Process of the Crossmember in Car Intermediate Floor

2013 ◽  
Vol 442 ◽  
pp. 593-598
Author(s):  
Xue Xia Wang ◽  
Peng Chong Guan ◽  
Hai Peng Li ◽  
Li Hui Wang ◽  
Na Zhang ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Process Parameters ◽  
Thickness Distribution ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Simulation Technology ◽  
Forming Process ◽  
Distribution Diagram ◽  
Simulation Results

Flanging and bending forming processes of the crossmember in car intermediate floor are investigated respectively by using numerical simulation technology. The numerical model of the crossmember was established and its press forming effect was simulated to determine the feasible process parameters affecting its manufacturability. Forming limit diagram and thickness distribution diagram are used to evaluate simulation results of different process schemes. And then optimum values of process parameters for flanging and bending are found, which can reduce the tendencies of wrinkling, springback and crackling during the stamping of the product.

scholarly journals The analysis of the parameters for deep drawing of cylindrical parts

2018 ◽  
Vol 178 ◽  
pp. 02011
Author(s):  
Dan Chiorescu ◽  
Esmeralda Chiorescu ◽  
Sergiu Olaru
Keyword(s):  
Finite Element ◽  
Deep Drawing ◽  
The Finite Element Method ◽  
Ansys Software ◽  
Forming Process ◽  
Thin Steel ◽  
Metal Forming Process ◽  
Cylindrical Parts ◽  
Cylindrical Cup ◽  
High Degree

Deep drawing is a very important metal forming process. Thin steel sheet is important material for manufacture of numerous products with deep drawing and stamping. Cold working provides also the possibility of making parts of various shapes, from the simplest to those with a high degree of complexity whose execution through other methods is uneconomical, difficult and sometimes even impossible. In this paper it is analyzed both experimentally and with the help of the finite element, the behavior of the blank during the cylindrical cup deep drawing process, using the ANSYS software program and the finite element method. A comparison is realized between the experimental and the analytical results, elaborating a representative set of problems that analyze the variation of the die punch clearance, movement of the punch and with or without lubrication. The results of the research are useful in developing a sensible design of experiments.

Experimental and Numerical Investigations of a Split-Ring Test for Springback

2006 ◽  
Vol 129 (2) ◽  
pp. 352-359 ◽  
Author(s):  
Z. Cedric Xia ◽  
Craig E. Miller ◽  
Feng Ren
Keyword(s):  
Experimental Data ◽  
Thickness Distribution ◽  
Transversely Isotropic ◽  
Ring Test ◽  
Stress Distributions ◽  
Opening Displacement ◽  
Split Ring ◽  
Punch Force ◽  
Hardening Models ◽  
Cylindrical Cup

This paper presents an in-depth experimental and numerical investigation of a split-ring test, which provides a simple yet effective benchmark for correlating forming and springback predictive capabilities with experimental measurements. The experimental procedure consists of deep drawing a circular 6111-T4 aluminum alloy into a cylindrical cup of 55mm depth, crosscutting nine rings each of 5mm wide from the cup, splitting the rings, and measuring their opening displacement, i.e., the springback amount. Experimental data obtained included punch force trajectories, drawn cup profile, thickness distribution after forming, and the ring openings after splitting. A numerical model is built to analyze the process, and both transversely isotropic and fully orthotropic yield criteria are investigated. Simulation results are validated against experimental data. A detailed numerical analysis is also conducted for stress distributions in each ring after each step and their relationship to the total springback amount. Stress and strain signatures suggested that the test is well suited for validating material models, such as anisotropic yield surface models and hardening models.

Investigation into Influence of Pre-Forming Depth on Multi-Stage Hydrodynamic Deep Drawing of Thin-Wall Cups with Stepped Geometries

2012 ◽  
Vol 457-458 ◽  
pp. 1219-1222 ◽  
Author(s):  
Yu Zhu ◽  
Min Wan ◽  
Ying Ke Zhou ◽  
Qing Hai Liu ◽  
Nan Song Zheng ◽  
...  
Keyword(s):  
Deep Drawing ◽  
Failure Modes ◽  
Thickness Distribution ◽  
Steel Part ◽  
Drawing Ratio ◽  
Thin Wall ◽  
Forming Process ◽  
Hydrodynamic Deep Drawing ◽  
Multi Stage ◽  
Thin Walled

Hydrodynamic deep drawing (HDD) is an effective method for manufacturing complicated and thin-walled parts. Aiming at the forming process of the stainless steel part with 0.4 mm thick and complex stepped geometries, the technology scheme of multi-stage HDD assisted by conventional deep drawing (CDD) is proposed in consideration of wrinkling and destabilization in the unsupported region of the conical wall, and finite element models are built. As a key process parameter, pre-forming depth on the quality of the parts is explored with assistance of numerical simulations and verification experiments. Furthermore, the failure modes, including wrinkling and fracture during forming process are discussed; meanwhile, the optimum pre-forming depth is realized. The results indicate that the technological method is proven to be feasible for integral forming of thin-walled parts with a large drawing ratio and stepped geometries; moreover, the parts with uniform thickness distribution and high quality are successfully formed by adopting optimum pre-forming depth.

Investigation on Forming Process of Automobile Trunk Side Panel Based on Numerical Simulation Technology

2013 ◽  
Vol 634-638 ◽  
pp. 2855-2860
Author(s):  
Hai Peng Li ◽  
Jia Wei Fan ◽  
Li Hui Wang ◽  
Xue Xia Wang ◽  
Ju Yuan Zhao
Keyword(s):  
Numerical Simulation ◽  
Process Parameters ◽  
Thickness Distribution ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Simulation Technology ◽  
Forming Process ◽  
Distribution Diagram ◽  
Side Panel ◽  
Design Cycle

The forming process of automobile trunk side panel was investigated, using numerical simulation technology, to acquire the feasible process parameters and improve the formability of the product. With the technology, the manufacturability working procedures and drawing process parameters of the product were analyzed, calculated and simulated to achieve optimum formability characteristics. The method effectively lowers the probability of springback, wrinkling and thickness reduction, and shortens design cycle and cost. Based on the simulation results including forming limit diagram and thickness distribution diagram, the feasible process parameters are determined.

Experimental and Numerical Investigations of a Split-Ring Test for Springback

2005 ◽  
Author(s):  
Z. Cedric Xia ◽  
Craig E. Miller ◽  
Feng Ren
Keyword(s):  
Experimental Data ◽  
Thickness Distribution ◽  
Transversely Isotropic ◽  
Ring Test ◽  
Stress Distributions ◽  
Opening Displacement ◽  
Split Ring ◽  
Punch Force ◽  
Hardening Models ◽  
Cylindrical Cup

This paper presents an in-depth experimental and numerical investigation of a split-ring test, which provides a simple yet effective benchmark for correlating forming and springback predictive capabilities with experimental measurements. The experimental procedure consists of deep drawing a circular 6111-T4 aluminum alloy into a cylindrical cup of 55mm depth, cross-cutting 9 rings of 5mm each from the cup, splitting the rings and measuring their opening displacement, i.e. the springback amount. Experimental data obtained included punch force trajectories, drawn cup profile, thickness distribution after forming, and the ring openings after splitting. A numerical model is built to analyze the process, and both transversely-isotropic and fully-orthotropic yield criteria are investigated. Simulation results are validated against experimental data. A detailed numerical analysis is also conducted for stress distributions in each ring after each step and their relationship to springback amount. Stress and strain signatures suggested that the test is well suited for validating material models such as anisotropic yield surface models and hardening models.

A Method of Improving Limiting Drawing Ratio：Differential Temperature Deep Drawing Based on Superplasticity

2011 ◽  
Vol 239-242 ◽  
pp. 392-397
Author(s):  
Xue Feng Xu ◽  
Ning Li ◽  
Gao Chao Wang ◽  
Hong Bo Dong
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
Coupled Analysis ◽  
Flowing Water ◽  
Finite Element Code ◽  
Uniform Thickness ◽  
Forming Process ◽  
Good Agreement

A thermal-mechanical coupled analysis of superplastic differential temperature deep drawing (SDTDD) with the MARC finite element code is performed in this paper. Initial drawing blank of an AA5083 bracket was calculated and adjusted according to the simulation result. During the SDTDD simulation, the power-law constitutive model of AA5083 was established as function of temperature and implanted in software MARC through new complied subroutine. Under the guide of the numerical simulation, the die was fabricated and the AA5083 bracket was successfully manufactured via superplastic differential temperature deep drawing. In forming practice, the temperature of female die was kept at 525°C, i.e. the optimal superplastic temperature of AA5083, and the punch was cooled by the flowing water throughout the forming process. The drawing velocity of punch was 0.1mm/s. Results revealed that the formed bracket had a sound uniform thickness distribution. Good agreement was obtained between the formed thickness profiles and the predicted ones.

Influencing Factors of AZ31B Sheet Deep Drawing

2011 ◽  
Vol 189-193 ◽  
pp. 88-91
Author(s):  
Jun Gao ◽  
Zhen Ming Yue ◽  
Shu Xia Lin
Keyword(s):  
Numerical Simulation ◽  
Deep Drawing ◽  
Experimental Approach ◽  
Elevated Temperatures ◽  
Heating Temperature ◽  
Thickness Distribution ◽  
Simulation Software ◽  
Forming Limit ◽  
Forming Process ◽  
Specific Strength

Magnesium alloys have been attracting much more attentions due to its low density, high specific strength and its lightweight during the past 30 years. In this paper, the deep drawing performance of AZ31B magnisium alloy sheets at elevated temperature was studied by the experimental approach. The results indicated that the formability of the AZ31B sheets at elevated temperatures could be improved significantly. The best external forming parameters can be obtained such as heating temperature of sheet, die-punch clearance, punch fillet radius, etc. Simulating the forming process by using the numerical simulation software, we investigated the stress-strain distribution, thickness distribution and forming limit, etc. The thickness distribution by the numerical simulation agrees well with the experimental results.

Numerical – Experimental Correlation of Sheet Hydroformed Component

2015 ◽  
Vol 651-653 ◽  
pp. 1140-1145
Author(s):  
Alessandro Spagnolo ◽  
Teresa Primo ◽  
Gabriele Papadia ◽  
Antonio del Prete
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
Complex Geometry ◽  
Thickness Distribution ◽  
Fluid Pressure ◽  
Experimental Tests ◽  
Element Analysis ◽  
Influence Of Process Parameters ◽  
Experimental Correlation ◽  
Hydroforming Process

Sheet hydroforming has gained increasing interest in the automotive and aerospace industries because of its many advantages such as higher forming potentiality, good quality of the formed parts which may have complex geometry. The main advantage is that the uniform pressure can be transferred to any part of the formed blank at the same time. This paper reports numerical and experimental correlation for symmetrical hydroformed component. Experimental tests have been carried out through the hydroforming cell tooling, designed by the authors thanks to a research project, characterized by a variable upper blankholder load of eight different hydraulic actuators. The experimental tests have been carried out following a factorial plane of two factors, with two different levels for each factor and three replicates for each test with a total of 12 tests. In particular two process parameters have been considered: blank holder force, die fluid pressure. Each factor has been varied between an High (H) and Low level (L). The order in which have been conducted the tests has been established through the use of the Minitab software, in order to ensure the data normality and the absence of auto-correlation between the tests. An ANOVA analysis has been performed, in addition, with the aim of evaluating the influence of process parameters on the thickness distribution of the component, its formability and feasibility. Finally, finite element analysis (FEA) was used to understand the formability of a material during the hydroforming process. In this paper, the commercial finite element code LS-Dyna was used to run the simulations. A good numerical – experimental correlation has been obtained.

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