OPTIMIZATION OF THE FORMING PROCESS OF GUTTER END CAP USING THE FINITE ELEMENT METHOD

The contribution deals with the optimization of the forming process with the use of FE analysis. The impact of the planar anisotropy and friction coefficient on the drawing process was evaluated in the numerical simulation. Optimization of metal blank size and shape with the use of metal forming simulation was also performed. Studied material was galvanized drawing quality steel which is used for the production of the rain gutter end cap. Effects of planar anisotropy and friction coefficient on the quality of steel stamping were evaluated with the use of FE simulation. The effect of anisotropy was also experimentally tested. The aim of this work was to determine the correct steel blank size and shape and to evaluate the effects of planar anisotropy on the thickness variation and wall wrinkling.

Reduce the Planar Anisotropy of AA6016 Aluminum Sheets by Texture and Microstructure Control

In order to produce a more isotropic Al-Mg-Si alloy sheet in the T4 temper, pre-annealed AA6016 hot rolled strips were cold rolled by conventional rolling, transverse rolling and an alternative rolling schedule. In this work, a weak and random texture was obtained in the alternative rolling sample, which was treated by solution treatment, as well as a fine and homogeneous recrystallized grain structure that reduced the earing percentage from 8.2% to 2.7%. An earing test was used to characterize the planar anisotropy of the AA6016 alloy. The crystallographic texture and microstructure of the AA6016 aluminum sheet were analyzed by X-ray diffraction and electron back scatter diffraction (EBSD) techniques. The earing percentage was reduced and eight-fold ears were produced in unidirectional rolled samples with strong β-fiber textures. Conversely, a higher earing percentage and four-fold ears were obtained for the alternative rolled sample, which was characterized by an appropriate combination of the Cube {001}<100> and stabilized BND {011}<3`22> [(φ1,¢,φ2) = (42°,45°,0°)] orientations. The main reason for the distinct earing profiles was the grain spatial distribution of textures formed during the cold rolling process. The dynamic recovery of the AA6016 alloy was promoted and both the nucleation and subsequent growth of the Cube orientation were suppressed by alternative rolling.

Effect of specimen orientation to the rolling direction on uniaxial tensile forming and failure limits

Alteration of forming and failure limits due to planar anisotropy of the sheet metal significantly affects the safe forming operation region and finally successfully manufacturing of a sheet metal formed component. This article presents the effect of planar anisotropy on uniaxial tensile properties, forming and failure limits of cold-rolled ferritic and dual-phase steels. In-situ three dimensional digital image correlation technique is used to measure the evolution of local strain components during uniaxial tensile test. For both the steels, necking limit is highest for the specimen at an orientation of 90° to rolling direction, while failure limit is highest for those specimen whose orientation is 45° to rolling direction for ferritic steel, and both 0° and 90° to rolling direction for dual-phase steel. Uniaxial tensile deformation path for ferritic steel holds lower slope than dual-phase steel as depicted in major versus minor strain plot.