A Study on Tool Wear of Sheet Metal Stamping Die Using Numerical Method

2010 ◽  
Vol 654-656 ◽  
pp. 346-349
Author(s):  
Xuan Zhi Wang ◽  
Syed H. Masood
Keyword(s):  
Tool Wear ◽  
Sheet Metal ◽  
High Strength Steels ◽  
High Strength ◽  
Control Parameters ◽  
Sheet Metal Stamping ◽  
Advanced High Strength Steels ◽  
Stamping Die ◽  
Metal Stamping ◽  
Metal Blank

Advanced high strength steels (AHSS) are increasingly used in sheet metal stamping in the automotive industry. In comparison with conventional steels, advanced high strength steel (AHSS) stampings produce higher contact pressures at the interface between draw die and sheet metal blank, resulting in more severe wear conditions, particularly at the draw die radius. The prediction of tool wear patterns for sheet metal stamping die is a highly challenging task as there are many control parameters involved in the production. This paper presents a numerical simulation methodology to analyse the influences of various control parameters on tool wear patterns of a sheet metal stamping die with different die radius arc profiles. The results of tool wear patterns provide informative guidelines for on-site production.

Optimisation of Die Radius Geometry in Sheet Metal Stamping

2011 ◽  
Vol 337 ◽  
pp. 350-353 ◽  
Author(s):  
Xuan Zhi Wang ◽  
S.H. Masood
Keyword(s):  
Tool Wear ◽  
Sheet Metal ◽  
High Strength Steels ◽  
High Strength ◽  
Sheet Metal Stamping ◽  
Advanced High Strength Steels ◽  
Metal Stamping ◽  
Contact Pressures ◽  
Abaqus Software

Advanced high strength steels (AHSS) are increasingly utilised in sheet metal stamping in the automotive manufacture. In comparison with conventional steels, AHSS stampings produce higher contact pressures at the interface between the tool-workpiece interface, leading to more severe wear conditions, particularly at the draw die radius. To minimise tool wear using this approach it would be necessary to optimise the shape for a particular combination of circular and high elliptical profiles. This paper presents a methodology to optimise a die radius profile. For this, a specialised software routine is developed and compiled for optimisation of die radius profiles to minimise or achieve uniform contact pressure (wear distribution) using Python computer programming language supported by Abaqus software. A detailed algorithm for the optimisation is explained. A case study based on the algorithm is also discussed.

An Engineering Approach to Improve the Stamping Robustness of High Strength Steels

2009 ◽  
Vol 131 (6) ◽  
Author(s):  
Wu-rong Wang ◽  
Bo Hou ◽  
Zhong-qin Lin ◽  
Z. Cedric Xia
Keyword(s):  
Sheet Metal ◽  
Weight Ratio ◽  
High Strength Steels ◽  
High Strength ◽  
Process Variations ◽  
Optimal Process ◽  
Sheet Metal Stamping ◽  
The Monte Carlo Method ◽  
Metal Stamping ◽  
Metal Properties

High strength steels (HSSs) are one of the light-weight sheet metals well suited for reducing vehicle weight due to their higher strength-to-weight ratio. However, HSS tend to have bigger variations in their mechanical properties due to more complex rolling techniques involved in the steel-making process. Such uncertainties, when combined with variations in the process parameters such as friction and blank holder force, pose a significant challenge in maintaining the robustness of HSS sheet metal stamping. The paper presents a systematic and robust approach, combining the power of the finite element method and stochastic statistics to decrease the sensitivity of HSS stamping in the presence of above-mentioned uncertainties. First, the statistical distribution of sheet metal properties of selected HSS is characterized from a material sampling database. Then a separate interval adaptive response surface methodology (RSM) is applied in modeling sheet metal stamping. The new method significantly improves the model accuracy when compared with the conventional RSM within a single interval. Finally, the Monte Carlo method is employed to simulate the stochastic response of material/process variations to stamping quality and to provide optimal process parameter designs to reduce the sensitivity of these effects. The experiment with the obtained optimal process design demonstrates the improvements of stamping robustness using small-batch experiments.

A study on the computer-aided measuring integration system for the sheet metal stamping die

2006 ◽  
Vol 177 (1-3) ◽  
pp. 138-141 ◽  
Author(s):  
Chen-Hua She ◽  
Chun-Cheng Chang ◽  
Yung-Chou Kao ◽  
Hsin-Yu Cheng
Keyword(s):  
Sheet Metal ◽  
Integration System ◽  
Sheet Metal Stamping ◽  
Stamping Die ◽  
Metal Stamping ◽  
Computer Aided

Experimental Study on Galling Behavior of Advanced High Strength Steel in Sheet Metal Forming

2012 ◽  
Vol 502 ◽  
pp. 36-40
Author(s):  
Ying Ke Hou ◽  
Shu Hui Li ◽  
Yi Xi Zhao ◽  
Zhong Qi Yu
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Sheet Material ◽  
High Strength Steels ◽  
High Strength ◽  
Forming Process ◽  
Advanced High Strength Steels ◽  
Sheet Materials ◽  
Materials Used

Galling is a known failure mechanism in many sheet metal forming processes. It limits the lifetime of tools and the quality of the products is affected. In this study, U-channel stamping experiments are performed to investigate the galling behavior of the advanced high strength steels in sheet metal forming . The sheet materials used in the tests are DP590 and DP780. In addition to the DP steels, the mild steel B170P1 is tested as a reference material in this study. Experimental results indicate that galling problem becomes severe in the forming process and the galling tendency can be divided into three different stages. The results also show that sheet material and tool hardness have crucial effects on galling performance in the forming of advanced high strength steels. In this study, DP780 results in the most heaviest galling among the three types of sheet materials. Galling performance are improved with increased hardness of the forming tool.

A Study of Springback of Sheet Metal Formed Parts Using ANSYS

2011 ◽  
Vol 291-294 ◽  
pp. 381-384
Author(s):  
Xuan Zhi Wang ◽  
Syed H. Masood ◽  
Daron Ng ◽  
Omar Dawwas
Keyword(s):  
Sheet Metal ◽  
Metal Forming ◽  
High Strength Steels ◽  
High Strength ◽  
Analysis Software ◽  
Element Analysis ◽  
Advanced High Strength Steels ◽  
Material Recovery ◽  
Formed Product ◽  
Forming Tools

Springback is one of main reason for inaccuracy of sheet metal formed product. Therefore prediction of springback is very important for production of precise products. Springback is an elastic material recovery after unloading of the forming tools, and causes variations and inconsistencies of final part dimensions. This is affected by various parameters involved in the process of sheet metal forming. The main aim of this paper is to investigate the springback of finished part by analysing and controlling the effects of the control parameters on the springback of advanced high strength steels (AHSS). This is done by modelling a deep-drawing process and analysing the results as determined on ANSYS finite element analysis software.

scholarly journals Time series analysis of tool wear in sheet metal stamping using acoustic emission

2017 ◽  
Vol 896 ◽  
pp. 012030 ◽  
Author(s):  
V. Vignesh Shanbhag ◽  
P. Michael Pereira ◽  
F. Bernard Rolfe ◽  
N Arunachalam
Keyword(s):  
Time Series ◽  
Acoustic Emission ◽  
Tool Wear ◽  
Time Series Analysis ◽  
Sheet Metal ◽  
Sheet Metal Stamping ◽  
Series Analysis ◽  
Metal Stamping

scholarly journals Investigation Effect of Spring Back on Bending Test of (DP590) Dual Phase Steel

2018 ◽  
Vol 2 (6) ◽  
pp. 55-62
Author(s):  
Muhamad Sani Buang ◽  
Keyword(s):  
Sheet Metal ◽  
Dual Phase Steel ◽  
High Strength Steels ◽  
High Strength ◽  
Bending Test ◽  
Dual Phase ◽  
Spring Back ◽  
Factors Affecting ◽  
Advanced High Strength Steels ◽  
Fitting In

: The use of advanced high strength steels as a metal in sheet metal forming in automotive industry currently has been increased where Advanced High Strength Steel (AHSS) especially Dual Phase (DP590) Steels have gained a great attention due to a combination of high strength and good formability. However, one of the major constraints in forming AHSS is the occurrence of high spring back caused by elastic relaxation after loading, which causes illness-fitting in part assembly and geometric deviation of the intended design. Spring back is the main problem of defect that occurs at sheet metal after the bending process which creates problems for the parts during the assembly. This paper presents an investigation the effect of spring back on bending test of Dual Phase Steel (DP590). Punch travel and thickness are among factors affecting the spring back behavior. Various parameter value; punch radius (5mm), die radius (5mm), die gap (70mm), thickness of specimen 1mm and 2mm, punch travel/stroke (25%, 50%, 75%, 100%) from 20 mm depth, punch speed (2mm/min) and Orientation of sheet cutting, which is in rolling (00°), diagonal (45°) and transverse (90°). From the analysis of V-bending test punch travel, thickness and orientation of sheet cutting are significant factor that affecting the spring back phenomena. The result form this experiment could be useful for design engineers and manufacturing engineers to make improvement of predict the spring back behavior and also to understanding the material properties of AHSS in order to eliminate spring back and achieve good final product.

Evaluation and Validation of Methods to Determine Limit Strain States with Focus on Modeling Ductile Fracture

2014 ◽  
Vol 622-623 ◽  
pp. 265-272
Author(s):  
Andreas Sabathil ◽  
Ingo Heinle ◽  
A. Lipp ◽  
J. Meinhardt ◽  
M. Merklein
Keyword(s):  
Ductile Fracture ◽  
Sheet Metal ◽  
High Strength Steels ◽  
High Strength ◽  
Limit Strain ◽  
Model Parameters ◽  
Element Analysis ◽  
Advanced High Strength Steels ◽  
Validation Experiment ◽  
Body In White

In the manufacturing process of body in white components made from sheet metal it is state of the art to accompany the process by means of finite element analysis. A main criterion for determining a feasible tool design and production process parameters is the prediction of material failure, which can be categorized in instability and ductile fracture. The ductile fracture failure mode is more likely to occur, as more advanced high strength steels and aluminum alloys are used for body in white components. Therefore different approaches have been presented to model ductile fracture over the past years. This task is more challenging when the material is exposed to arbitrary loading paths that can occur in deep drawing processes. However there is no guideline for sheet metal forming applications to determine which models for predicting ductile fracture are suitable, which experiments are necessary and how calibration of model parameters and validation of model prediction can be performed. Additionally there is no standard established that prescribes the evaluation of limit strain states from experiments. Suitable limit strain states are a basic requirement for prediction of ductile fracture as they are used for calibration of fracture models. In this paper, two methods for evaluation of limit strains are discussed and applied to tensile specimens with circular hole and circular cut outs made from aluminum alloy AlSi0.6Mg0.5. One validation experiment is used to investigate failure prediction that is based on limit strain states from different evaluation methods.

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