A Hybrid Intelligent Systems Approach for Die Design in Sheet Metal Forming

2000 ◽  
Vol 16 (5) ◽  
pp. 370-375 ◽  
Author(s):  
R. Pilani ◽  
K. Narasimhan ◽  
S. K. Maiti ◽  
U. P. Singh ◽  
P. P. Date
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Intelligent Systems ◽  
Systems Approach ◽  
Die Design ◽  
Hybrid Intelligent Systems

A Study on the Effective Die Design in Sheet Metal Forming to Improve the Productivity

2014 ◽  
Vol 592-594 ◽  
pp. 806-810
Author(s):  
C.N. Ashok Kumar
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Material Handling ◽  
Operation Time ◽  
Handling Time ◽  
Die Design ◽  
Machine Method ◽  
Proper Design ◽  
Major Factors

Productivity is one of the major factors that affect the profit of any industry or any product. In manufacturing industries, the productivity is showing the efficiency of the production unit. It depends on many factors such as technology, machine, method, management etc. In this study, method of manufacturing is considered and analyzed how it affects the productivity. Productivity is normally expressed as the number of units produced / unit time. Sheet metal forming is one of the major manufacturing processes and used for most of the products. The proper design of die is important in sheet metal forming processes. This article discusses how the Combination Die can improve the productivity. For this study, a product “U Clamp” is considered. The Product requires piercing, bending and parting off operations. The Combination Die is designed and fabricated for the product and tested. Data on operation time, material handling time are collected, analyzed and discussed.

scholarly journals Die design optimization on sheet metal forming with considering the phenomenon of springback to improve product quality

2018 ◽  
Vol 154 ◽  
pp. 01105 ◽  
Author(s):  
Agung Setyo Darmawan ◽  
Agus Dwi Anggono ◽  
Abdul Hamid
Keyword(s):  
Product Quality ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Die Design ◽  
Forming Limit ◽  
Improve Product Quality ◽  
Blank Holder Force ◽  
Blank Holder ◽  
Improve Product

The process of sheet metal forming is one of the very important processes in manufacture of products mainly in the automotive field. In sheet metal forming, it is added a certain size at the die to tolerate a result of the elasticity restoration of material. Therefore, when the product is removed from the die then the process elastic recovery will end within the allowable tolerance size. Extra size of the die is one method to compensate for springback. The aim of this research is to optimize the die by entering a springback value in die design to improve product quality that is associated with accuracy the final size of the product. Simulation processes using AutoForm software are conducted to determine the optimal parameters to be used in the forming process. Variations the Blank Holder Force of 77 N, 97 N, and 117 N are applied to the plate material. The Blank Holder Force application higher than 97 N cannot be conducted because the Forming Limit Diagram indicates the risk of tearing. Then the Blank Holder Force of 37 N, 57 N and 77 N are selected and applied in cup drawing process. Even though a few of wrinkling are appear, however there is no significant deviation of dimension between the product and the design of cup.

A Finite Element Based Die Design Algorithm for Sheet-Metal Forming on Reconfigurable Tools

2000 ◽  
Vol 123 (4) ◽  
pp. 489-495 ◽  
Author(s):  
Simona Socrate ◽  
Mary C. Boyce
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Design Procedure ◽  
Die Design ◽  
Tool Geometry ◽  
Stretch Forming ◽  
Design Algorithm ◽  
Die Surface

Tooling cost is a major contributor to the total cost of small-lot production of sheet metal components. Within the framework of an academic/industrial/government partnership devoted to the development of a reconfigurable tool for stretch forming, we have implemented a Finite Element-based procedure to determine optimal die shape. In the reconfigurable forming tool (Hardt, D. E. et al., 1993, “A CAD Driven Flexible Forming System for Three-Dimensional Sheet Metal Parts,” Sheet Metal and Stamping Symp., Int. Congress and Exp., Detroit, MI, SAE Technical Paper Series 930282, pp. 69–76.), the die surface is created by the ends of an array of square pins, which can be individually repositioned by computer driven servo-mechanisms. An interpolating polymer layer is interposed between the part and the die surface to attain a smooth pressure distribution. The objective of the die design algorithm is to determine optimal positions for the pin array, which will result in the desired part shape. The proposed “spring-forward” method was originally developed for matched-die forming (Karafillis, A. P., and Boyce, M. C., 1992, “Tooling Design in Sheet Metal Forming using Springback Calculations,” Int. J. Mech. Sci., Vol. 34, pp. 113–131.; Karafillis, A. P., and Boyce, M. C., 1996, “Tooling And Binder Design for Sheet Metal Forming Processes Compensating Springback Error,” Int. J. Tools Manufac., Vol. 36, pp. 503–526.) and it is here extended and adapted to the reconfigurable tool geometry and stretch forming loading conditions. An essential prerequisite to the implementation of the die design procedure is the availability of an accurate FE model of the entire forming operation. The particular nature of the discrete die and issues related to the behavior of the interpolating layer introduce additional challenges. We have first simulated the process using a model that reproduces, as closely as possible, the actual geometry of the discrete tool. In order to optimize the delicate balance between model accuracy and computational requirements, we have then used the information gathered from the detailed analyses to develop an equivalent die model. An automated algorithm to construct the equivalent die model based on the discrete tool geometry (pin-positions) is integrated with the spring-forward method, to generate an iterative die design procedure that can be easily interfaced with the reconfiguring tool. The success of the proposed procedure in selecting an optimal die configuration is confirmed by comparison with experimental results.

A Hybrid Draw Die Optimization Technique for Sheet Metal Forming

2004 ◽  
Vol 126 (3) ◽  
pp. 582-590 ◽  
Author(s):  
Adrian Scott-Murphy ◽  
S. Kalyanasundaram ◽  
M. Cardew-Hall ◽  
Peter Hodgson
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Optimization Technique ◽  
Die Design ◽  
Analytical Models ◽  
Limiting Factor ◽  
Knowledge Based ◽  
Time Required

Recent years have seen considerable advances in the use of Finite Element (FE) modeling techniques, to the point where they can be used confidently to predict the output of the sheet metal forming system. The limiting factor in the use of FE analysis in the optimization process is now shifting from the accuracy of simulations, to the time required to optimize the system. This paper proposes a new approach aimed at reducing the time to optimize a draw die design, through a combination of Finite Element Modeling, semi-analytical models, and a knowledge based expert system.

A new approach for inverse analysis of springback in a sheet-bending process

2008 ◽  
Vol 222 (11) ◽  
pp. 1363-1374 ◽  
Author(s):  
A Behrouzi ◽  
B M Dariani ◽  
M Shakeri
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Three Dimensional ◽  
Die Design ◽  
Element Analysis ◽  
New Approach ◽  
Bending Process ◽  
Process Convergence

In sheet metal-forming processes, the final product can deviate from the target shape as a result of springback. Several approaches have been proposed for analysis of springback and compensating for its error. In this paper, a new approach for springback analysis is presented based on inverse modelling. The springback occurs at the last step of the process and the final geometry of the workpiece can be obtained at the end of direct process modelling. By applying inverse springback analysis, iterative die design becomes possible from the end of the process. Applying bending theory in an inverse algorithm, compensation of springback error is performed in the V-bending process. Convergence of the inverse approach is compared with the direct approach. The inverse springback analysis is developed for three-dimensional analysis of sheet metal forming by applying the explicit—implicit finite element method. Inverse springback modelling of asymmetric and large springback processes is feasible by this new algorithm. The capability and accuracy of this method are investigated for various symmetric and asymmetric processes by comparing results of the method by three-dimensional finite element analysis and V-bending experimental results.

ИССЛЕДОВАНИЕ ТОЧНОСТИ ДЕТАЛЕЙ, ПОЛУЧАЕМЫХ ПРИ РАЗДЕЛИТЕЛЬНЫХ ОПЕРАЦИЯХ В ПЕРЕНАЛАЖИВАЕМЫХ ШТАМПАХ

2018 ◽  
pp. 52-63
Author(s):  
Е. А. Фролов ◽  
В. В. Агарков ◽  
С. И. Кравченко ◽  
С. Г. Ясько
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Balance Method ◽  
Experiment Planning ◽  
Practical Recommendations

To determine the accuracy of the readjustable punches for separating operations (perforation + punching out) of sheet-metal forming, the accuracy parameters were analyzed using the random balance method using the method of experiment planning. Analytical dependencies are obtained to determine the values of deviation of the outer and inner contour dimensions of perforated and punched out sheet parts. From the dependencies obtained, it is possible to estimate and predict the value of deviation in the dimensions of the resulting part at any time during the operation of the punch. Practical recommendations on the calculation of the actuating dimensions of the working elements (stamping punch, matrix) of readjustable punches are offered.

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