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.

Recovery of Diamond and Cobalt Powder from Polycrystalline Drawing Die Blanks via Ultrasound-Assisted Leaching Process—Part 1: Process Design and Efficiencies

The treatment of industrial polycrystalline diamond (PCD) blanks in aqua regia at atmospheric pressure between 333 K and 353 K was performed via the ultrasound-assisted leaching process to investigate whether the influence of ultrasound is beneficial. Cobalt content in the solution and in the blanks was monitored as well as the effects of leaching temperature, solid-to-liquid ratio, and PCD blank size. The use of intermittent and permanent ultrasound helped reduce the leaching time and thus energy consumption by up to 50%. In all trials with ultrasound, higher temperature only has a slight effect. Solid-to-liquid ratio does not have a positive or negative impact. A new process design was tested using an innovative experimental setup for ultrasound-assisted leaching aiming at maximum cobalt and diamond recovery from PCD and final reuse of fine PCD for cutting and polishing other hard materials in different important industrial applications.

The Effect of Elevated Temperature on the Drawability of a Circular Deep Drawn Metal Cup

Product quality is one of the important aspects in deep drawing practice and the variation in process temperature was claimed to improve the quality. Therefore, in this research, the effect of the heating temperature on the drawability of a circular metal cup has been investigated. Firstly, circular metal cups of aluminium, mild steel and stainless steel were drawn from the blank diameters of 60 mm, 65 mm, and 70 mm. The experiment was conducted at room temperature followed by at 100 °C, 150 °C and 200 °C. The Taguchi method was selected as the design of experiment approach, and L9 (34) array design methodology was adopted in this experimental research. The drawability was measured based on the punching force needed to deform the sheet metal blanks. The deep drawing process was conducted at room, and elevated temperature conditions and the response factor was analysed and compared through the analysis of variance (ANOVA) statistical approach. The results obtained from ANOVA indicate that the blank material has a significant influence on the deep drawing process followed by the blank size, heating temperature and heating technique. The optimal parameter combinations are blank diameter of 60 mm, heating temperature of 200 °C and the die and punch heating technique. Out of the three materials investigated, aluminium has a better drawability compared to mild steel and stainless steel.

Effects of the Molding Method and Blank Size of Green Body on the Sintering Densification of Magnesia

The bulk density of sintered magnesia is significantly influenced by molding methodology and blank size of the green body during dry pressing. The entrapped air in the green body plays a critical role in determining the bulk density of magnesia samples. Herein, high-density magnesia samples, with different sizes, are prepared by using vacuum compaction molding and conventional compaction molding. The physical properties, such as bulk density and pore size distribution, and morphology or as-sintered magnesia samples were characterized by using Archimedes method, mercury porosimetry, and scanning electron microscopy (SEM). The results indicate that the bulk density of conventional compaction magnesia samples decreased below 3.40 g·cm−3 with the increase of thickness due to the presence of entrapped-air induced large pores and intergranular cracks. In addition, the large pores and intergranular cracks in conventionally-compacted samples are observed by SEM images. However, vacuum compaction of magnesia samples resulted in a bulk density of higher than 3.40 g·cm−3 for all thicknesses. Moreover, the defects in vacuum-compacted magnesia samples are mainly in the form of small circular pores.

Evaluation of Draw Beads Influence on Intricate Shape Stamping Drawing Process

Paper concerns evaluation of influence of shape, size and location of rectangular and semicircular draw beads on sheet-metal forming process. For analysis the simulations of forming process of selected two types of intricate shape stampings with similar ground plan and with approximately the same height from steel strip DC04 with the use of models of optimal blanks made by BSE (Blank Size Engineering) modul of simulation program Dynaform 5.7 were carried out. From simulations of forming process in simulation program Dynaform 5.7 followed that the most suitable is drawing without use of draw beads because cracks in stamping bottom corners do not arise. In the case of undesirable secondary waviness in the walls of intricate shape stamping the drawing with draw beads could be used but it would be necessary to increase the radius at the bottom of both stampings alternatively to choose another material with higher formability.

The Springback Predication for a Pillar Reinforcement Plate with Drawing Surface Optimization

More and more high strength steel panels are used in the Auto assembly for the reason of reducing pollution emissions and fuel consumption. The springback predication with different drawing styles for A pillar reinforcement plate is studied in this paper. The drawing process is optimized with different height drawbead for getting a reasonable forming result without obvious crack areas. An open drawing is used to study the possibility of reducing the blank size, but the measuring results show that the springback value predicted with close ends drawing is very close to the real tryout results and more lower than open ends drawing. So the open end drawing method can not be used in the tryout from the perspective of reducing the springback value.