Effects of Process Parameters on the Formability of Miniature Layered Cups

2015 ◽  
Vol 661 ◽  
pp. 69-76
Author(s):  
Tsung Chia Chen ◽  
Ming Long Xu
Keyword(s):  
Flow Rule ◽  
Copper Sheet ◽  
Forming Process ◽  
Elastic Plastic ◽  
Coulomb’S Friction ◽  
Updated Lagrangian Formulation ◽  
Updated Lagrangian ◽  
Finite Deformation Theory ◽  
The Relationship ◽  
Experimental Difference

Based on materials, different punch radii (0.3, 0.35, 0.4, 0.45, and 0.5 mm), two sets of diameter-diameter ratio 1.(.167, 1.25, 1.33, 1.4167, and 1.5) and 2.(1.6, 1.45, 1.33, 1.231, and 1.143), and two sets of depth ratio 1.(1.3, 1.4, 1.5, 1.6, and 1.7) and 2.(2.14, 1.875, 1.67, 1.5, and 1.36) are used for the stamping processes to analyze the simulation and experimental difference in copper sheet-metal (C1100) miniature layered cups. Prandtl-Reuss flow rule is integrated with finite deformation theory and Updated Lagrangian Formulation (ULF) to establish the incremental elastic-plastic deformation Finite Element Method in Coulomb’s Friction Law for simulating the miniature layered cup process. Generalized rmin algorithm is utilized in the forming process for dealing with elastic-plastic behaviors and die contact. From the simulation data, the relationship among deformation history, punch load, and punch stroke, the stress-strain distribution, and the distribution of the thinnest thickness by different punch radii are acquired.

scholarly journals Experimental and Numerical Analysis of Stainless Steel Microtube in Flaring Process

2014 ◽  
Vol 2014 ◽  
pp. 1-8
Author(s):  
Tsung-Chia Chen ◽  
Wei-Kai Ceng
Keyword(s):  
Finite Element ◽  
Cone Angle ◽  
Experimental Result ◽  
Flow Rule ◽  
Forming Process ◽  
Element Analysis ◽  
Punch Load ◽  
The Coefficient Of Friction ◽  
Updated Lagrangian ◽  
The Relationship

This study, with experiments and comparisons, aims to analyze the difference of stainless (SUS316L) microtubes in the flaring forming among dies with various semicone angles (35°, 40°, 45°, 50°, and 55°). The flow rule by Prandtl-Reuss combined with the finite element deformation theory and updated Lagrangian formulation (ULF) is applied to establish the finite element analysis equation for an incremental elastoplastic deformation to simulate the microtube flaring process. The broadrminalgorithm is utilized in the forming process for the elastoplastic state and die contact. The simulation data allow acquiring the deformation traceability, the relationship between punch load and punch stroke, the distribution of stress and strain, the distribution of the thinnest thickness resulted from dies with different semicone angles, and the distribution of flaring radius caused by dies with distinct semicone angles in the forming process. The experimental result presents similar results to the relationship between punch load and punch stroke and the simulation of the coefficient of frictionμ=0.05, revealing the analysis being suitable for the analysis of microtube cone angle flaring process. The analysis and experimental results show that the thinnest thickness of the microtube increases with increasing semicone angles of dies and the maximal flaring radius of microtubes increases with increasing semicone angles of dies.

Analysis of Optimal Vertical in Angular U-Bending Process

2011 ◽  
Vol 337 ◽  
pp. 346-349
Author(s):  
Tsung Chia Chen
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Lagrangian Formulation ◽  
Blank Holder ◽  
Elastic Plastic ◽  
Metal Sheets ◽  
Bending Process ◽  
Updated Lagrangian Formulation ◽  
Updated Lagrangian ◽  
Tool Angle

This study aims to analyze the effects of angular U-bending process on the springback of metal sheets. Based on Updated Lagrangian Formulation (ULF), the 3D incremental elastic-plastic Finite Element Method was inferred to simulate the U-bending process of metal sheets. The die/blank holder profile with angles of α=-4°, α=-2°, α=0°, α=2°, α=4° and die/punch profile with radiuses of Rp=Rd=6.0mm were analyzed to determine the influence of tool angles on the springback. With different tool angles to proceed the U-bending process of metal sheets, it is found that the larger or smaller die angles, the more springback magnitude. When perpendicular U-sheets are required, θ1 of the U-sheet presents 90 degree on the tool angle α=-1.2° and θ2 shows 90 degrees on the tool angle α=-0.4°. The aim of this study is to investigate the effects of angle variables on the springback in the U-bending process and to obtain useful data from the industrial field.

An Adaptive Remeshing Procedure for Modeling the Clinch Forming Process

2012 ◽  
Author(s):  
Abdallah Sahyoun ◽  
Alain Rassineux ◽  
Jean-Marc Roëlandt ◽  
Carl Labergère ◽  
Khémais Saanouni
Keyword(s):  
Applied Load ◽  
Sheet Thickness ◽  
Field Variable ◽  
Tool Geometry ◽  
Forming Process ◽  
Adaptive Remeshing ◽  
Updated Lagrangian Formulation ◽  
Updated Lagrangian ◽  
Error Indicators ◽  
Diffuse Approximation

This work presents the case of a press clinching commonly met in the industry and denoted as TOX. The mechanical strength of the assembly is highly dependent on the final geometry of the clinched joint and among the numerous parameters which govern the process (applied load, lubrication, sheet thickness, friction, mechanical behavior of materials), the tool geometry plays a major role in the evolution of the final shape of the clinched joint. One of the objectives of this work is to provide an accurate numerical evolution of the final geometry of the clinched joint by the use of an adaptive remeshing procedure including error indicators and field variable transfer built by a meshless technique denoted as Diffuse Approximation. The resolution of the updated Lagrangian formulation is based on a static explicit approach (ABAQUS). Our numerical results are validated in comparison with experimental data.

Study on the Thermo-Elastic-Plastic Cutting Model for 3-D Tool with Chip Breaker

1998 ◽  
Vol 120 (4) ◽  
pp. 265-274 ◽  
Author(s):  
Zone-Ching Lin ◽  
Yan-Liang Zheng
Keyword(s):  
Simulation Model ◽  
Cutting Force ◽  
Three Dimensional ◽  
Initial Contact ◽  
Chip Breaker ◽  
Elastic Plastic ◽  
Updated Lagrangian Formulation ◽  
Updated Lagrangian ◽  
Chip Separation ◽  
Cutting Model

This paper used large deformation finite element theory, updated Lagrangian formulation, finite difference method, and incremental theory to develop a three-dimensional thermo-elastic-plastic simulation model for a tool with chip breaker. Both the critical strain energy density theory and the tool feed geometrical location were introduced as the chip separation criterion for cutting. The algorithm of tool movement geometrical limitations was used to examine and correctly the node so as to conform to real cutting conditions. In this model, the tool moved step by step in the simulation, which ran from the initial contact between tool and workpiece to the formation of steady cutting force. Finally, the numerical simulation model proposed in this paper was used to analyze the changes in workpiece and chip shapes, stress, strain rate, residual stress, temperature and cutting force of mild steel workpiece under different chip breaker lengths. The results were also compared with those from tools without chip breaker. The findings indicate that the chip breaker length affects the shorter the chip breaker length, the better the effects of chip breaker, and the lower the values of the aforementioned physical properties.

Experimental and Numerical Analysis of Titanium Alloy Microtube Tube-End Nosing Forming

2018 ◽  
Vol 920 ◽  
pp. 16-21
Author(s):  
Chien Yi Chen ◽  
Tsung Chia Chen
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Friction Coefficient ◽  
Cone Angle ◽  
Contact Problems ◽  
Plastic State ◽  
Flow Rule ◽  
Forming Process ◽  
Element Analysis ◽  
Updated Lagrangian

This study is mainly based on five sets of mold cone angle and friction coefficient of micro-tube tube end necking forming analysis, and the tool cone angle of 60° experimental verification is carried out to analyze the titanium alloy (Grade 1) micro-tube for different mold cone angle and the different friction coefficient caused by the difference between the shrinkage forming. In this paper, Prandtl-Reuss's plastic flow rule, combined with finite element deformation theory and updated Lagrangian formulation (ULF) concept, establish an incremental elasto-plastic finite element analysis program for simulating the miniature tube end necking. The forming process also uses the generalized rmin algorithm to deal with elasto-plastic state and contact problems. From the simulation data of necking process, deformation history, punch load and punch stroke, stress and strain distribution is obtained. The analysis results show that by increasing the mold cone angle and friction coefficient, the thickness tends to be thicker in the certain area.

Numerical Simulation and Process Optimization of Automotive Friction Materials in Warm Pressing Forming

2013 ◽  
Vol 788 ◽  
pp. 57-60
Author(s):  
Chun Cao ◽  
Chun Dong Zhu ◽  
Chen Fu
Keyword(s):  
Process Optimization ◽  
Heating Temperature ◽  
Maximum Energy ◽  
Heating Time ◽  
Product Performance ◽  
Forming Process ◽  
Friction Materials ◽  
Forming Technology ◽  
The Relationship ◽  
Temperature Heating

Warm pressing forming technology has been gradually applied to the forming of automotive friction materials. How to ensure product performance to achieve the target at the same time achieve the maximum energy saving is the research focus of this study. In this paper, by using finite element method, the field of automotive friction materials in warm pressing forming was analyzed, reveals the relationship between the temperature field and the heating temperature/heating time. Furthermore, the energy consumption was analyzed and compared it with hot pressing forming process. The results will have significant guiding to the process optimization in warm pressing forming.

Numerical Investigation of Size Effect on Dry Friction Behavior in Micro Upsetting Process

2014 ◽  
Vol 997 ◽  
pp. 321-324
Author(s):  
Wei Zheng ◽  
Guang Chun Wang ◽  
Bing Tao Tang ◽  
Xiao Juan Lin ◽  
Yan Zhi Sun
Keyword(s):  
Friction Coefficient ◽  
Size Effect ◽  
Dry Friction ◽  
Normal Pressure ◽  
Friction Model ◽  
Strain Hardening Exponent ◽  
Forming Process ◽  
Friction Behavior ◽  
Initial Yield Stress ◽  
Coulomb’S Friction

After modifying the Wahime/Bay friction model, a new friction model suitable for micro-forming process without lubrication is established. In this model, it is shows that the friction coefficient is a function of strain hardening exponent, the normal pressure and the initial yield stress of material. Based on the experimental data, the micro-upsetting process is simulated using the proposed friction model. The simulation results are used to investigate the size effect on the dry friction behavior. It is found that the Coulomb’s friction coefficient is dropping with miniaturization of specimens when the amount of reduction is not too large.

scholarly journals Optimization of Superplastic Forming Process of AA7075 Alloy for the Best Wall Thickness Distribution

2021 ◽  
Vol 6 (4) ◽  
pp. 251-261
Author(s):  
Manh Tien Nguyen ◽  
Truong An Nguyen ◽  
Duc Hoan Tran ◽  
Van Thao Le
Keyword(s):  
Wall Thickness ◽  
Deformation Temperature ◽  
Numerical Optimization ◽  
Thickness Distribution ◽  
Superplastic Forming ◽  
Forming Process ◽  
Wall Thickness Distribution ◽  
Surface Method ◽  
Series Of Experiments ◽  
The Relationship

This work aims to optimize the process parameters for improving the wall thickness distribution of the sheet superplastic forming process of AA7075 alloy. The considered factors include forming pressure p (MPa), deformation temperature T (°C), and forming time t (minutes), while the responses are the thinning degree of the wall thickness ε (%) and the relative height of the product h*. First, a series of experiments are conducted in conjunction with response surface method (RSM) to render the relationship between inputs and outputs. Subsequently, an analysis of variance (ANOVA) is conducted to verify the response significance and parameter effects. Finally, a numerical optimization algorithm is used to determine the best forming conditions. The results indicate that the thinning degree of 13.121% is achieved at the forming pressure of 0.7 MPa, the deformation temperature of 500°C, and the forming time of 31 minutes.

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