Deformable Sheet Metal Fixturing: Principles, Algorithms, and Simulations

1996 ◽  
Vol 118 (3) ◽  
pp. 318-324 ◽  
Author(s):  
W. Cai ◽  
S. J. Hu ◽  
J. X. Yuan
Keyword(s):  
Sheet Metal ◽  
Rigid Bodies ◽  
Fixture Design ◽  
Total Deformation ◽  
Element Analysis ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Manufacturing Operations ◽  
Nonlinear Programming Methods ◽  
Simulation Package

Fixture design is an important consideration in all manufacturing operations. Central to this design is selecting and positioning the locating points. While substantial literature exists in this area, most of it is for prismatic or solid workpieces. This paper deals with sheet metal fixture design. An “N-2-1” locating principle has been proposed and verified to be valid for deformable sheet metal parts as compared to the widely accepted “3-2-1” principle for rigid bodies. Based on the “N-2-1” principle algorithms for optimal fixture design are presented using finite element analysis and nonlinear programming methods to find the best “N” locating points such that total deformation of the deformable sheet metal is minimized. A simulation package called OFixDesign is introduced and numerical examples are presented to validate the “N-2-1” principle and optimal sheet metal fixture design approach.

scholarly journals Impact of Fixture Design Sheet Metal Assembly Variation

2002 ◽  
Author(s):  
Jaime A. Camelio ◽  
S. Jack Hu ◽  
Dariusz J. Ceglarek
Keyword(s):  
Sheet Metal ◽  
Design Methodology ◽  
Design Procedure ◽  
Fixture Design ◽  
Element Analysis ◽  
Sheet Metal Parts ◽  
Nonlinear Programming Methods ◽  
The Impact ◽  
Sheet Metal Assembly

This paper presents a new fixture design methodology for sheet metal assembly processes. The proposed approach focuses on the impact of fixture position on the dimensional quality of sheet metal parts after assembly, considering part and tooling variation and assembly springback. The optimization algorithm combines finite element analysis and nonlinear programming methods to find the optimal fixture position such that the assembly variation is minimized. The optimal fixture design methodology enables to significantly reduce the assembly variation in the presence of part and tooling variation. A case study is presented to demonstrate the design procedure.

Optimisation of Springback Predicted by Experimental and Numerical Approach by Using Response Surface Methodology

2005 ◽  
Vol 6-8 ◽  
pp. 753-762
Author(s):  
R. Bahloul ◽  
Phillippe dal Santo ◽  
Ali Mkaddem ◽  
A. Potiron
Keyword(s):  
Response Surface ◽  
Sheet Metal ◽  
Design Method ◽  
Fem Simulation ◽  
Numerical Approach ◽  
Tool Geometry ◽  
Nose Radius ◽  
Element Analysis ◽  
Metal Parts ◽  
Sheet Metal Parts

Bending has significant importance in the sheet metal product industry. Moreover, the springback of sheet metal should be taken into consideration in order to produce bent sheet metal parts within acceptable tolerance limits and to solve geometrical variation for the control of manufacturing process. Nowadays, the importance of this problem increases because of the use of sheet-metal parts with high mechanical characteristics (High Strength Low Alloy steel). This work describes robust methods of predicting springback of parts in 3D modelling subjected to bending and unbending deformations. Also the effects of tool geometry in the final shape after springback are discussed. The first part of this paper presents the laboratory experiments in wiping die bending, in which the influence of process variables, such as die shoulder radius, punch-die clearance, punch nose radius and materials properties were discussed. The second part summarises the finite element analysis by using ABAQUS software and compares these results with some experimental data. It appeared that the final results of the FEM simulation are in good agreement with the experimental ones. An optimisation methodology based on the use of experimental design method and response surface technique is proposed in the third part of this paper. That makes it possible to obtain the optimum values of clearance between the punch and the die and the optimum die radius which can reduce the springback without cracking and damage of product.

Press Forging Forming of Stepped Holes in Thick Sheet Metal

2013 ◽  
Vol 706-708 ◽  
pp. 234-237
Author(s):  
Xu Jun Cao ◽  
Ke Sheng Wang ◽  
Yu Han ◽  
Chong Chao Lin
Keyword(s):  
Sheet Metal ◽  
Effective Strain ◽  
Extrusion Process ◽  
Thick Sheet ◽  
Element Analysis ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Thick Sheet Metal ◽  
Deform 3D ◽  
Good Agreement

Press forging forming of thick sheet metal is a combined extrusion process, which is put forward in the presently study. A new technological scheme for a two-step press forging of stepped holes in a thick metal sheet was proposed. Finite element analysis on the two-step process is carried out by using DEFORM-3D. Distributions of effective strain and effective stress were obtained. The study showed that the process not only can form the stepped holes, but also can increase the surface quality and strength of stepped holes in sheet metal parts, According to the numerical simulations process parameter, an experimental die was designed, the simulation results were in good agreement with the experimental data.

FE Simulation of Sheet Metal Forming – State of the Art in Automotive Industry

2005 ◽  
Vol 6-8 ◽  
pp. 13-18 ◽  
Author(s):  
H.J. Haepp ◽  
M. Rohleder
Keyword(s):  
Sheet Metal ◽  
Automotive Industry ◽  
Development Process ◽  
High Strength Steels ◽  
Feasibility Studies ◽  
High Strength ◽  
Element Analysis ◽  
Early Design ◽  
Metal Parts ◽  
Sheet Metal Parts

Nowadays feasibility studies using finite element analysis are performed in very early design phases of sheet metal parts forming. Further, simulation technology is used to optimize the first forming stage. Because of the ever intensifying international competition and the increased use of high-strength steels and aluminum alloys, the absorption of springback deviations is a great challenge, especially in the automotive industry. The application of numerical computation to predict springback deviations and to create compensated die designs in early design phases of sheet metal parts forming becomes essential. At DaimlerChrysler the numerically based compensation of springback deviations during the die development process of complex car parts is achieved. However, developments to optimize and compensate dies automatically or to predict form deviations on assemblies are still necessary.

An Approach to Automate Concept Generation of Sheet Metal Parts Based on Manufacturing Operations

2008 ◽  
Author(s):  
Jay Patel ◽  
Matthew I. Campbell
Keyword(s):  
Sheet Metal ◽  
Early Stage ◽  
Concept Generation ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Manufacturing Operations ◽  
Rectangular Patch ◽  
Modeling Software ◽  
Metal Design ◽  
New Perspective

This paper describes an approach to automate the design for sheet metal parts that are not only novel and manufacturable but also satisfies multiple objective functions such as material cost and manufacturability. Unlike commercial software tools such as Pro/SHEETMETAL which aids the user in finalizing and determining the sequence of manufacturing operations for a specified component, our approach starts with spatial constraints in order to create the component geometries and helps the designer design. While there is an enormous set of parts that can feasibly be generated with sheet metal, it is difficult to define this space systematically. To solve this problem, we currently have 88 design rules that have been developed for four basic sheet metal operations: slitting, notching, shearing, and bending. A recipe of the operations for a final optimal design is then presented to the manufacturing engineers thus saving them time and cost. The technique revealed in this paper represents candidate solutions as a graph of nodes and arcs where each node is a rectangular patch of sheet metal, and modifications are progressively made to the sheet to maintain the parts manufacturability. They are presented in the form of Standard Tessellation Language files (.stl) that can be transferred into available modeling software for further analysis. The overall purpose of this research is to provide creative designs to the designer granting him/her a new perspective and to check all the solutions for manufacturability in the early stage of design process. An example sheet metal design problem is shown in this paper with some of the preliminary designs that our approach created.

Location optimization of interchangeable parts in sheet metal assembly

2016 ◽  
Vol 232 (10) ◽  
pp. 1848-1857
Author(s):  
Honglun Huan
Keyword(s):  
Sheet Metal ◽  
Complete Bipartite Graph ◽  
Perfect Match ◽  
Prediction Method ◽  
Stiffened Panel ◽  
Flexible Beam ◽  
Element Analysis ◽  
Location Optimization ◽  
Metal Parts ◽  
Sheet Metal Parts

Stiffened panel is a kind of structure that is widely used in aviation manufacturing. Some sheet metal parts in the structure have three characteristics: place-interchangeable, large quantity and stochastic variation caused by spring back or distortion in manufacturing process, which prominently impacts the assembly variation. In order to minimize the influence and improve the assembly quality of stiffened panel, a model based on flexible beam is established and a simplified and approximate assembly variation prediction method is obtained. Furthermore, for the interchangeable sheet metal parts, the assembly location optimization method based on the algorithm of perfect match of weighted complete bipartite graph is proposed. At last, case study on a fuselage panel assembly is implemented. The finite element analysis results show the reliability of the simplified variation prediction method and the necessity of assembly location optimization.

A Knowledge-Based System for Manufacturability Assessment of Deep Drawn Sheet Metal Parts

2011 ◽  
Vol 473 ◽  
pp. 749-756 ◽  
Author(s):  
Vishal Naranje ◽  
Shailendra Kumar
Keyword(s):  
Sheet Metal ◽  
Low Cost ◽  
Metal Parts ◽  
Knowledge Based System ◽  
Sheet Metal Parts ◽  
Manufacturing Operations ◽  
Knowledge Based ◽  
Sources Of Knowledge ◽  
Geometrical Features ◽  
System Output

In this paper a knowledge based system (KBS) for checking manufacturability of deep drawn sheet metal parts is described. For the development of proposed system technical knowledge acquired from different sources of knowledge acquisition is framed in the form of production rules of ‘IF-THEN’ variety and then coded using AutoLISP language. For consultation, the user loads the system into the prompt area of AutoCAD. The proposed system generates friendly prompt eliciting from the user for data pertaining to the job at hand. The system output includes recommendations on suitability of geometrical features of the part for required manufacturing operations. The system is flexible and its knowledge base can be extended and modified as old manufacturing facilities are discarded or newer ones are acquired in a particular enterprise. Effectiveness of the proposed system is demonstrated by taking an example of an industrial sheet metal part. The low cost of implementation of proposed system makes it affordable for small and medium scale sheet metal industries.

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