Scribd Logo
Upload

Welcome to Scribd!

  • 526 1

    Uploaded by

    mis2hijos
    7 views4 pages
    w

    Original Title

    526-1

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document
    w

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    7 views4 pages

    526 1

    Uploaded by

    mis2hijos
    w

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 4
    Progressive Die Sequence Design for Deep Drawing Round Cups Using Finite Element Analysis ‘Taylan Altan Nitin Jain Xinoxiang Shi ERC for Net Shape Manufacturing, ‘The Ohio State University, Columbus, OH 43210 Gracious Ngalile Department of Mechanical and Aerospace Engineering, North Carolina State University, Raleigh, NC 27685 e-mail gngsile@eos.nest.eda Bryan Pax Brent Harman Greg Homan Pax Machine Works, Celina, OH 45822 ‘A methodology for progressive die sequence design for forming round cups using fnte clement method (FEM) based suaularions is diseusted. The process sequence design developed was applied 10 forming of an awomotive part and was compared with the design obtained from past experiance. The methodology proposed In tts paper has shown thr ihe integration of design experience ‘and FEM sinultions can enkonce the robustness ofthe proce ‘dure for die design sequence ad reduces the die developmen cost ‘onsieraby. [DOK 10.111511 2039942), 1. Introduetion In the stamping indus, the design of progressive dis relies hei on pst xpaienss and sovrtlprotatye ce tyovts Pe me I (Para) shows the process soquene of © rod fart mah tired using pogssive die. A pogesive ole prfons 9s ‘es of fandamenal forming operations at two oF me sation rng each pes soe athe sip stock moves tough te se ‘Tae mos excl and challenging fsues inthis ask ae ov to determin (te miu numberof eged forming sep {i he conexponding tooling shapes wie maintaining the spe fed thickness dation he formed part This posed re- {sites extensive sores and inresse the proses dvstogmene ime an cost A compute aided epprosch is highly dsinbl 0 Assign robust progressive die sequonce quickly and at redbced ‘Knowge-ased ystems have been explored to determine r- pie forming rages in dsp ravings to-Omensiona or tng problems [1-3] Knowle for hess sytem drive fom plsicty theory, experimental sls, and the empires! oo ‘one ty te Msecurng rgecing Os fe peice i th Aste Joona ce Mimerome Sct seo Eaonane, Hotere Sonny 20,204 fel mans ected Deemer 8 308- avi oneed reo, 366 / Vol. 128, FEBRUARY 2006 Copyright © 2008 by ASME fs how of field engineers. This approach has shown some succes. However, it cannot consider the process conditions that aro not already stored in the knowledge base. Yo calier studies, elated to the subject of this pape, Cao [6] used numerical simulations and iy analysis to optimize che umber of forming stages in 2 tuli-step deep drawing problem. Kim [1] eartied out tool design analysis for multi-step drawing using the finite clement method (PEND. tn dhese studies, only design improvements in exiting multi-step tooling were carried ou Tn the present study, an allempt is made to develop @ FE simakionsbesed design strategy Tor progressive die sequence in ‘deep drawing of round cups. The analysis was carried out by & ‘commercial implicit FEM code, Deroms 20. The design sequence ‘obisined from FEM was compared with thot obtained using past ‘experience and trl-ané-esor approach. The results indicate that the PEM based stroegy is approximately equivalent to thal proc ticed by eagineess wit many’ years of experience 2. Die Design Strategy for FEM Based Approach ‘Tho objective ofthis study was to design the progressive die sequence for an automotive part show in Fig. 2 (Pact B) using FEM simulation. The die design procedure must determine: {a} number of forming stoges, (8) tool geometry for each stage (punchiaie diameter, punch comer and die comer rai), () draw- ing depth for each stage and () bank holder force fr each stage In order to develop an appropriate de design statepy, for forming pam B (Fig. 2), the forming stages of an example par, part A shown in Fig. 1, were investigated using FE siultions. Geomet- Fie parameters for various slages ofthe example part were pro vided by the stamping company sponsoring this research. The following design guidelines were obtained from this investigation Higher draw ratios ave used in the nial forming stages. Figure 3 shows the trends forthe variation of punch dim~ eters and maximum wall thinaing. The punch diameter is reduced rapidly duting the inital stages of deformation and relatively iti in the Iter stages. Based on ibis rend, it was decided to constrain the maximam wall thinning below 45% inthe first forming stage of part B. Inthe example pact, A, the ratio ofthe pure comer reds 1 die corner radios Was kept to less than 1 in all he forming stages, ie. the ratio varied from 0.75 to 095, This condition wa taken into ac count in determining the punch corner sad die corner ra {or various forming sages of part B. The example pat, A, wih a eight of 19 mm was menue ‘ured using st forming tages. Since the height of part B is 80 mm, we assumed that this part would requir more than six forming tags. 3. Process Sequence Design The design guidelines discussed above and others obtained From dic desiga handbooks (8] were applied in the design of pro- _nesive die sequence for part B. Figure 4 shows the flo chart of te stops conducted to daermine the parameters ofthe fis. form ing stage for part B using FEM. 3.41 Simulation Mode. The simulation model used is shown in Fig. 5, The gcomeuy was modeled over a unit radian about the Z axis due to axisymmetic deformation mode. Tho sheet was meshed with aaisymmeuric quadrilateral clement wih eight ek ments along the thickness (0 capture thickness distribution. The dies wore modeled tobe rigid and the sites sin relation For the Adefocming material was #6576 MPa, A Coulomt frie eflicien, .=0.1, was selected as the thinning distribution from FEM simulation using this value that matched experimental re- Sults forthe example par A. The initial blank diameter, dy, was ‘erermined so be 165:79m through volume constancy using the part dimensions given in Fig. 2.‘Tho punch velocity of 150 mays ‘Wat used in the simulations. ‘Transactions of the ASIME, eEeODKesoeBDas Fig. 1 Around cup manufactured using progressive dies (Part a 32. BlonkeHolder Force for the First Stage. The blank bolder fore forthe frst tage wos determined by performing, simulations with diferent bans-boldr foes. the benkcboler force Is tsufcen, the FEM simulaion shone hat the blank holder will move upwards (Fig. 5 result in ange wrntig a the frst fering stge the minima blank hole force of $0 kN was selected 1 prevent wrlkling Le, the upwan movement of the Dank hold A snilar suategy was used to determine the ‘lnk Hoe forces in subsequent forming sages 33. Panch Diameter, Die Diameter and Drawing Depth for ‘the First Stage. The punch diameter andthe drawing depth have ‘maximum influence on wall thinning. The maximum wall hing ‘was constrained to be less than 4% in the fist slage. Mercove, in the frst stage, the cup is drawn completely without ange to pst ‘more material ino the die cavity, Table | shows the simuladon ‘nalrix wsed to determine the optimum (Gimensions to constrain {he wall shinning below 4% and minimize the number of forming stages) punch diameter foc the fst stage, The draw ratios of 1.68, [.6 and 1.55 were obtained from die design handbook [8] forthe inal determination of punch diameters. The punch diameters of 100, 97, and 95 ram were ealeulated from these ratios. The die clearance was tken 2s 1Ltg while fps the inital sheet thickness. ‘The last column in Table 1 shows the maximo wall thinning 5 anc Diam) gee ees ‘Maxie Wl hing Fig. 3 Variation of the punch dlameter and wall thinning in progressive forming stages (example par, A) Journal of Manufacturing Seience and Engineering Ci fe d= fa? + Adh~ 340dr Used appropiate LOR water to deternineprebsbiepunctidie diameter Grandad ‘Chea ial poncho an ‘ie commer raat Cor design, Tasloook L_bentooo_ J “GondoctF ENimutaionta determine drening depth ‘oer not lave ange ‘CoaseeFEMeimalaoas vag ponahfdie ameter (we 42) obiained Som SLD vais

    You might also like