Progressive Die Sequence Design for Deep Drawing Round Cups Using Finite Element Analysis

2004 ◽  
Vol 128 (1) ◽  
pp. 366-369 ◽  
Author(s):  
Taylan Altan ◽  
Nitin Jain ◽  
Xiaoxiang Shi ◽  
Gracious Ngaile ◽  
Bryan Pax ◽  
...  
Keyword(s):  
Finite Element ◽  
Die Design ◽  
Development Cost ◽  
Element Analysis ◽  
Progressive Die ◽  
Sequence Design ◽  
Process Sequence ◽  
Process Sequence Design ◽  
Automotive Part ◽  
Design Experience

A methodology for progressive die sequence design for forming round cups using finite element method (FEM) based simulations is discussed. The process sequence design developed was applied to forming of an automotive part and was compared with the design obtained from past experience. The methodology proposed in this paper has shown that the integration of design experience and FEM simulations can enhance the robustness of the procedure for die design sequence and reduces the die development cost considerably.

An Automated Process Sequence Design and Finite Element Simulation of Axisymmetric Deep Drawn Components

2014 ◽  
Vol 136 (3) ◽  
Author(s):  
Ali Fazli ◽  
Behrooz Arezoo ◽  
Mohammad H. Hasanniya
Keyword(s):  
Finite Element ◽  
Computer Aided Design ◽  
Die Design ◽  
Automatic Process ◽  
Blank Holder ◽  
Cad System ◽  
Process Sequence ◽  
Element Simulation ◽  
Process Sequence Design ◽  
Aided Design

A computer-aided design (CAD) system is developed for automatic process design and finite element (FE) modeling of axisymmetric deep drawn components. Using the theoretical and experimental rules, the system initially designs the process sequence of the component. The obtained process sequence is automatically modeled in abaqus software and the system tests whether failure occurs. The failure is supposed to happen when the fracture is predicted in FE simulation. If failure is predicted, the system changes the appropriate process parameters and carries out the simulation process again until all drawing stages are successful. The system returns the requested parameters for die design such as part geometries in middle stages, drawing forces, blank-holder forces, die, and punch profiles radii. The system is successfully tested for some components found in industry and handbooks.

A Study on the Process Sequence Design of a Tub for Washing Machine Container by Finite Element Analysis

2006 ◽  
Vol 532-533 ◽  
pp. 809-812
Author(s):  
Joong Yeon Lim ◽  
Dong Hwan Jang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Design Criteria ◽  
The Finite Element Method ◽  
Washing Machine ◽  
Forming Process ◽  
Sequence Design ◽  
Process Sequence ◽  
Conventional Process ◽  
Process Sequence Design

A design methodology was applied to manufacturing a tub for washing machine container. The finite element method was employed to investigate the forming process. The forming process of sheet metal into a tub for washing machine container was selected as a model process to demonstrate the design of improved process sequence which has fewer operation stages than in conventional process. The design procedures made extensive use of the finite element method which can deal with elastic-plastic modeling. A one stage process sequence to form an initial blank to final product has been simulated to obtain information on metal flow requirements. Loading simulation for conventional manufacturing process sequence has been also simulated to evaluate the design criteria. From the simulation results of conventional process sequence, it is concluded that the design criteria should include thickness uniformity in finished tub and maximum punch load within the limit of available press capacity. The newly designed sequence has two forming operations and can achieve net-shape manufacturing, while the conventional process sequence has three forming operations. The design procedure proposed in this study could be considered for the method applied to the development of process sequence design in general.

Forging Process Analysis of 6061 Aluminum Alloy Motorcycle Brake Parts

2021 ◽  
Vol 901 ◽  
pp. 176-181
Author(s):  
Tung Sheng Yang ◽  
Chieh Chang ◽  
Ting Fu Zhang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Metal Forming ◽  
Process Analysis ◽  
Surface Hardness ◽  
Dimensional Accuracy ◽  
Die Design ◽  
Element Analysis ◽  
Forging Process

This paper used finite element analysis of metal forming to study the forging process and die design of aluminum alloy brake parts. According to the process parameters and die design, the brake parts were forged by experiment. First, the die design is based on the product size and considering parting line, draft angle, forging tolerance, shrinkage and scrap. Secondly, the finite element analysis of metal forming is used to simulate the forging process of aluminum alloy brake parts. Finally, the aluminum alloy brake levers with dimensional accuracy and surface hardness were forged.

A Process Sequence Design of Multi-Step Cold Extrusion Process for Hollow Parts

2005 ◽  
pp. 4195-4198
Author(s):  
Jae Hyun Shim ◽  
J.H. Ok ◽  
Hyoung Jin Choi ◽  
H.S. Koo ◽  
Beong Bok Hwang
Keyword(s):  
Extrusion Process ◽  
Cold Extrusion ◽  
Sequence Design ◽  
Process Sequence ◽  
Process Sequence Design

Finite Element Simulation of the Yoke Spline under Hot Forging Process

2020 ◽  
Vol 982 ◽  
pp. 106-111
Author(s):  
Surasak Suranuntchai
Keyword(s):  
Finite Element ◽  
Hot Forging ◽  
Fem Simulation ◽  
Die Design ◽  
Forming Process ◽  
Element Simulation ◽  
Metal Forming Process ◽  
Automotive Part ◽  
Forging Die ◽  
Hot Forging Process

Nowadays, finite element method (FEM) has been widely used to forecast metal forming process, to analysis problems of workpiece, to decrease production cost, and to save time of die design. This work studied the use of FEM as a tool to design a hot forging die for producing an automotive part named Yoke Spline. The part was made from carbon steel grade S45CVL0. There are three processes to produce Yoke Spline, including the buster, rougher, and finisher processes. The objective of the study was to increase efficiency of production by 5%. To achieve this objective, it was necessary to design a new die in the buster process by using FEM to analyze the die size and shape. The new die must produce the workpieces without any defects. The defects regularly found in the forging workpieces are the dimension out of specification, the under filling, and the crack. The sizes of the buster upper die cover are the width and depth. The die width of 44.5, 46.5 and 49.5 millimeters and the die depth of 25, 28 and 31 millimeters were used in the hot forging simulation. From FEM simulation results, it was found that the die width of 46.5 millimeters and the die depth of 28 millimeters were the best to form workpieces without any defects. In summary, the simulation and experimental results were compatible.

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