Optimization of Sheet Metal Process Parameters of a Shield Case Piece Using Computer Simulation

2006 ◽  
Vol 510-511 ◽  
pp. 330-333
Author(s):  
M.C. Curiel ◽  
Ho Sung Aum ◽  
Joaquín Lira-Olivares
Keyword(s):  
Sheet Metal ◽  
Thickness Distribution ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Physical Processes ◽  
Forming Process ◽  
Element Analysis ◽  
One Step ◽  
Range Of Values ◽  
Principal Strains

Numerical simulations based on Finite Element Analysis (FEA) are widely used to predict and evaluate the forming parameters before performing the physical processes. In the sheet metal industry, there are basically two types of FE programs: the inverse (one-step) programs and the incremental programs. In the present paper, the forming process of the shield case piece (LTA260W1-L05) was optimized by performing simulations with both types of software. The main analyzed parameter was the blankholding force while the rest of the parameters were kept constant. The criteria used to determine the optimum value was based on the Forming Limit Diagram (FLD), fracture and wrinkling of the material, thickness distribution, and the principal strains obtained. It was found that the holding force during the forming process deeply affects the results, and a range of values was established in which the process is assumed to give a good quality piece.

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.

Incremental Sheet Forming with an Industrial Robot – Forming Limits and Their Effect on Component Design

2005 ◽  
Vol 6-8 ◽  
pp. 457-464 ◽  
Author(s):  
L. Lamminen
Keyword(s):  
Sheet Metal ◽  
Industrial Robot ◽  
Forming Limit Diagram ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Point Of View ◽  
Forming Limit ◽  
Forming Process ◽  
3D Cad ◽  
Component Design

Incremental sheet forming (ISF) has been a subject of research for many research groups before. However, all of the published results so far have been related to either commercial ISF machines or ISF forming with NC mills or similar. The research reported in this paper concentrates on incremental sheet forming with an industrial robot. The test equipment is based on a strong arm robot and a moving forming table, where a sheet metal blank is attached. The tool slides on the surface of the sheet and forms it incrementally to the desired shape. The robot is capable of 5-axis forming, which enables forming of inwards curved forms. In this paper the forming limit diagram (FLD) for ISF with the robot is presented and it is compared with conventional forming limit diagrams. It will be shown that the conventional FLD does not apply to incremental forming process. Geometrical accuracy of sample pieces is also studied. Cones of different shapes are formed with the robot equipment and their correspondence with the 3D CAD model is evaluated. The results are compared with other results of accuracy of incremental sheet forming, reported earlier by other researchers. The third issue covered in this article is a product development point of view to incremental sheet forming. In addition to fast prototyping and low volume production of sheet metal parts, ISF brings new possibilities to sheet metal component design and manufacturing. These possibilities can only be exploited if design rules, that will take the possibilities and limitations of the method into account are created for ISF.

APPLICATION OF FORMING LIMIT CRITERIA BASED ON PLASTIC INSTABILITY CONDITION TO METAL FORMING PROCESS

2008 ◽  
Vol 22 (31n32) ◽  
pp. 5680-5685
Author(s):  
SEONG-CHAN HEO ◽  
TAE-WAN KU ◽  
JEONG KIM ◽  
BEOM-SOO KANG ◽  
WOO-JIN SONG
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Thin Sheet ◽  
Plastic Instability ◽  
Theoretical Background ◽  
Forming Limit ◽  
Preliminary Evaluation ◽  
Forming Process ◽  
Element Analysis

Metal forming processes such as hydroforming and sheet metal forming using tubular material and thin sheet metal have been widely used in lots of industrial fields for manufacturing of various parts that could be equipped with mechanical products. However, it is not easy to design sequential processes properly because there are various design variables that affect formability of the parts. Therefore preliminary evaluation of formability for the given process should be carried out to minimize time consumption and development cost. With the advances in finite element analysis technique over the decades, the formability evaluation using numerical simulation has been conducted in view of strain distribution and final shape. In this paper, the application of forming limit criteria is carried out for the tube hydroforming and sheet metal forming processes using theoretical background based on plastic instability conditions. Consequently, it is confirmed that the local necking and diffuse necking criteria of sheet are suitable for formability evaluation of both hydroforming and sheet metal forming processes.

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.

Prediction of Limiting Strains for Square Pattern – Square Hole Perforated Commercial Pure Aluminium Sheets

2012 ◽  
Vol 548 ◽  
pp. 382-386 ◽  
Author(s):  
G. Venkatachalam ◽  
S. Narayanan ◽  
Narayanan C. Sathiya
Keyword(s):  
Sheet Metal ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Pure Aluminium ◽  
Element Analysis ◽  
Material Condition ◽  
Geometrical Features ◽  
Perforated Sheet ◽  
Commercial Aluminium ◽  
Aluminium Sheets

Forming limit diagram (FLD) is the most appropriate tool used to obtain the safe strain region in sheet metal forming industries. This FLD is based on limiting values of major and minor strains. This Limiting strain is the strain at the onset of fracture / necking in a sheet metal. It is influenced by the material / condition of the material, strain condition in geometrical features of a sheet metal. In this paper, square pattern – square holed, perforated commercial aluminium sheets are considered for the study. The limiting strain for the above perforated sheet metals is predicted using finite element analysis. It is found that the limiting strain is controlled by percentage of open area, ligament ratio and hole size.

scholarly journals Viscous Backpressure Forming And Feasibility Study of Hemispherical Aluminum Alloy Parts

2021 ◽  
Author(s):  
Tiejun Gao ◽  
Jiabin Zhang ◽  
Kaixuan Wang
Keyword(s):  
Finite Element Analysis ◽  
Aluminum Alloy ◽  
Forming Limit Diagram ◽  
Loading Path ◽  
Forming Limit ◽  
Distribution Law ◽  
Forming Process ◽  
Element Analysis ◽  
Technical Feasibility ◽  
Forming Limit Diagrams

Abstract Hemispherical aluminum alloy parts are extensively used in modern aerospace and other manufacturing fields. However, wrinkling and cracking easily occur due to the large deformation of the parts, which leads to a complicated forming process. This research proposes a viscous backpressure forming method for hemispherical aluminum alloy parts. The forming limit diagram of LF2 sheet is established through the forming limit experiments. By the combination of finite element analysis and experimental verification, the forming process of the parts under different viscous backpressure and loading path conditions as well as the distribution law of stress-strain and wall thickness of the parts, are obtained. By comparing with the forming limit diagrams, technical feasibility of this forming process is discussed. The research results show that qualified parts can be formed using the viscous backpressure forming method under the conditions of viscous backpressure loading throughout the process with the backpressure at or above 12MPa. This provides a reference for the backpressure forming of hemispherical aluminum alloy parts.

Experimental Study on Residual Formability of Single Point Incrementally Formed Part

2019 ◽  
Author(s):  
Chetan P. Nikhare
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Forming Limit ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Conventional Process

Abstract A substantial increase in demand on the sheet metal part usage in aerospace and automotive industries is due to the increase in the sale of these products to ease the transportation. However, due to the increase in fuel prices and further environmental regulation had left no choice but to manufacture more fuel efficient and inexpensive vehicles. These heavy demands force researchers to think outside the box. Many innovative research projects came to replace the conventional sheet metal forming of which single point incremental forming is one of them. SPIF is the emerging die-less sheet metal forming process in which the single point tool incrementally forces any single point of sheet metal at any processing time to undergo plastic deformation. It has several advantages over the conventional process like high process flexibility, elimination of die, complex shape and better formability. Previous literature provides enormous research on formability of metal during this process, process with various metals and hybrid metals, the influence of various process parameter, but residual formability after this process is untouched. Thus, the aim of this paper is to investigate the residual formability of the formed parts using single point incremental forming and then restrike with a conventional tool. The common process parameters of single point incremental forming were varied, and residual formability was studied through the conventional process. The strain and thickness distribution were measured and analyzed. In addition, the forming limit of the part was plotted and compared.

Forming Limit Prediction of BCC Materials under Non-Proportional Strain-Path by Using Crystal Plasticity

2012 ◽  
Vol 201-202 ◽  
pp. 1110-1116
Author(s):  
Mei Yang ◽  
Xiao Yan Zhang ◽  
Hao Wang
Keyword(s):  
Sheet Metal ◽  
Crystal Plasticity ◽  
Strain Path ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Slip Systems ◽  
Plasticity Model ◽  
Forming Process ◽  
Crystal Plasticity Model ◽  
Microstructure Effect

In this paper, the forming limit of a body-centered cubic (BCC) sheet metal under non-proportional strain-path is investigated by using the Marciniak and Kuczynski approach integrated with a rate-dependent crystal plasticity model. The prediction model has been proved to be effective in predicting Forming Limit Diagram (FLD) of anisotropic sheet metal with FCC type of slip systems[1]. The same model has been used to study the FLD under non-proportional strain-path of BCC slip systems numerically and experimentally. The agreement between the experiments and simulations is good. With crystal plasticity model well describing the crystal microstructure effect, our model can be used to predict the FLD of BCC sheet metal under complicated strain path in plastic forming process with good accuracy.

scholarly journals Experimental And Theoretical Determination Of Forming Limit Curve

2015 ◽  
Vol 60 (3) ◽  
pp. 1881-1886
Author(s):  
J. Adamus ◽  
K. Dyja ◽  
M. Motyka
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Fracture Initiation ◽  
Forming Limit ◽  
Forming Process ◽  
Element Analysis ◽  
Metal Forming Process

Abstract The paper presents a method for determining forming limit curves based on a combination of experiments with finite element analysis. In the experiment a set of 6 samples with different geometries underwent plastic deformation in stretch forming till the appearance of fracture. The heights of the stamped parts at fracture moment were measured. The sheet - metal forming process for each sample was numerically simulated using Finite Element Analysis (FEA). The values of the calculated plastic strains at the moment when the simulated cup reaches the height of the real cup at fracture initiation were marked on the FLC. FLCs for stainless steel sheets: ASM 5504, 5596 and 5599 have been determined. The resultant FLCs are then used in the numerical simulations of sheet - metal forming. A comparison between the strains in the numerically simulated drawn - parts and limit strains gives the information if the sheet - metal forming process was designed properly.

scholarly journals PADDLE SHAPE OPTIMIZATION FOR HOLE-FLANGING BY PADDLE FORMING THROUGH THE USE OF A PREDEFINED STRAIN PATH IN FINITE ELEMENT ANALYSIS

2019 ◽  
Vol 19 (2) ◽  
pp. 83-98 ◽  
Author(s):  
Lemopi Isidore BESONG ◽  
Johannes BUHL ◽  
Markus BAMBACH
Keyword(s):  
Finite Element ◽  
Strain Path ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Element Analysis ◽  
High Speeds ◽  
The Right ◽  
Hole Flanging ◽  
Bulge Formation ◽  
Principal Strains

This research investigates a novel hole-flanging process by paddle forming through the use of finite element (FE) simulations. Paddles of different shapes rotating at high speeds were used to deform clamped sheets with pre-drilled holes at their centers. The results of the simulations show that the paddle shape determines the geometry and principal strains of the formed flanges. A convex-shaped paddle forms flanges with predominant strains in the left quadrant of the forming limit diagram (FLD). However, the convex paddle promotes unwanted bulge formation at the clamped end of the flange. A concave paddle forms flanges with no bulge but the principal strains of elements in the middle section of the flange are in the right quadrant of the FLD which indicates an increased probability for crack occurrence. An optimization of the paddle shape was conducted to prevent bulging at the clamped end while avoiding crack occurrence. The paddle shape was optimized by mapping the deformation of some elements along the flange length to a pre-defined strain path on the FLD while maintaining the bulge height within the desired geometric tolerance. The radii and lengths of the paddle edge were varied to obtain an optimum paddle shape.

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