Accuracy of Conventional Finite Element Models in Bulk-Forming of Micropins From Sheet Metal

2019 ◽  
Vol 7 (1) ◽  
Author(s):  
M. Kraus ◽  
T. Hufnagel ◽  
M. Merklein
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Process Analysis ◽  
Basic Process ◽  
The Finite Element Method ◽  
High Agreement ◽  
Bulk Forming ◽  
High Production Rate ◽  
High Production ◽  
Material Utilization

The ongoing miniaturization trend in combination with increasing production and functional volume leads to a rising demand for metallic microparts. Bulk forming of microparts from sheet metal provides the potential for mass production of those components by an extensive simplification of the handling. The advantage of a high production rate contrasts with the disadvantage of a low utilization of material. In this context, it is necessary to investigate suitable measures to increase the material utilization. To save cost intensive trial and error tests, numerical analysis could be an appropriate method for a basic process investigation. In this work, a validation with experimental results in the macro- and microscale was used to investigate the eligibility of the finite element method (FEM) for a basic process analysis. For a high transferability, the finite element (FE) models were validated for various tribological conditions and material states. The results reveal that there is a high agreement of the experimental and numerical results in the macroscale. In microscale, conventional FEM shows inaccuracies due to the negligence of size effects in the discretization of the process. This fact limits the application of conventional FE-programs. Furthermore, the results show that lubricated and dry formed blanks lead to the same friction force and process result in the microscale. In addition, the basic formability of the prestrengthened pins in further forming stages was experimentally demonstrated.

A Contribution to the Optimisation of a Simple Shear Test

2009 ◽  
Vol 410-411 ◽  
pp. 467-472 ◽  
Author(s):  
Marion Merklein ◽  
M. Biasutti
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Shear Test ◽  
The Finite Element Method ◽  
Simple Shear Test ◽  
Material Parameters

The finite element method is a widely used tool in sheet metal forming. The quality of the results of such an analysis depends largely on the applied constitutive model and its material parameters, which have to be determined experimentally. These data are relevant on the choice of the yield criterion among the wide range of options available in the commercial applications implementing the finite element method. Since the accuracy of material parameters estimation is therefore crucial, investigations were performed with an Al-Mg sheet alloy and a mild steel sheet to optimize a Miyauchi-based simple shear test. This method is one of the basic ways to investigate the plastic properties of a sheet metal up to large strains, which is very important for numerical analysis of sheet metal forming processes. Aim of the test is to determine the shear stress-strain correlation. In order to enhance the quality of the experimental results the detection of the deformation’s field, trough an optical measurement system, and the methodology for its evaluation are focus of the present study.

A Study on the Development of Tool Planning for REF SILL OTR-R/L Auto-Body Panel by Using Forming Analysis

2012 ◽  
Vol 628 ◽  
pp. 461-468
Author(s):  
D.W. Jung ◽  
D.H. Kim ◽  
B.C. Kim
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Sheet Metal ◽  
Deformation Behaviour ◽  
Good Prediction ◽  
The Finite Element Method ◽  
Forming Analysis ◽  
Auto Body ◽  
Body Panel ◽  
Element Method

The characteristics of the sheet metal process include the loss of material during the process, short processing time and excellent price and strength. The sheet metal process with the above characteristics is commonly used in the industrial field, but in order to analyze irregular field problems, a reliable and economical analysis method are needed. The finite element method is a very effective method to simulate the forming processes with a good prediction of the deformation behaviour. Among the finite element method, the static-implicit finite element method is applied effectively in order to analyze the real-size auto-body panel stamping processes, which include the forming stage.

Accumulator Roll Analysis Using the Finite Element Method

1999 ◽  
Author(s):  
Hazel M. Pierson ◽  
Daniel H. Suchora ◽  
Anthony V. Viviano
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Comparative Approach ◽  
The Finite Element Method ◽  
Roll Design ◽  
Roll Body ◽  
Finite Element Software ◽  
Fea Model ◽  
Finite Element Package ◽  
The Impact

Abstract The purpose of this study was to develop a method to analyze various designs of non-driven accumulator rolls using a static finite element software package. This would allow the engineer to determine how the various components of the roll design contribute to or lessen the deflection of and stresses in the roll body when it is loaded by sheet metal passing over o under it. The method outlined is intended mainly for use when an advanced dynamic finite element package that incorporates contact elements is not available and when a comparison of various roll designs is desired. First, an approximation of the pressure on the roll body caused by the force of the sheet metal as it wrapped over or under the roll was determined. Then using the finite element package ALGOR, an FEA model of a standard accumulator roll design was loaded with this pressure and the stresses and deflections were calculated. Next, components of this basic roll design were varied in the FEA model. These were the location of the stiffeners and the thickness of the roll body, the end plates, and the stiffeners. A comparative approach was then used to assess the impact each of these variations in roll design had oh the deflection of and the stresses in the roll.

In-Plane Torsion Testing of Sheet Metal

1977 ◽  
Vol 19 (5) ◽  
pp. 213-220 ◽  
Author(s):  
R. Sowerby ◽  
Y. Tomita ◽  
J. L. Duncan
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Work Hardening ◽  
Finite Element Approximation ◽  
Stress And Strain ◽  
Element Approximation ◽  
The Finite Element Method ◽  
Hardening Material ◽  
Torsion Testing ◽  
Stress And Strain Distribution

In this paper, the ‘in-plane’ torsion testing of sheet metal is examined. The test itself was first proposed by Marciniak in order to ascertain the work hardening behaviour and fracture strain of sheet metals. In the original work, the analysis was based on the assumption that the material was rigid-work hardening. The present work attempts a more rigorous solution, assuming the material to be elastic-work hardening. A finite-element approximation is employed to calculate the stress and strain distribution across the sheet metal annulus at various stages in the deformation process. A comparison is made between the results from the finite-element method and those based on a rigid-work hardening material. For certain annulus geometries, excellent agreement is obtained between both sets of results.

scholarly journals Force Prediction in Robotized Ultrasonic Sheet Metal Forming Based on Finite Element Analysis and Artificial Neural Networks

2021 ◽  
Author(s):  
Vytautas Ostasevicius ◽  
Agne Paulauskaite-Taraseviciene ◽  
Ieva Paleviciute ◽  
Vytautas Jurenas ◽  
Paulius Griskevicius ◽  
...  
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Single Point ◽  
The Finite Element Method ◽  
Element Analysis ◽  
The Coefficient Of Friction ◽  
Artificial Neural ◽  
Artificial Neural Network Ann ◽  
Implicit Data ◽  
Workpiece Interaction

Abstract The forces acting in the process of single point incremental forming (SPIF) change the geometry of the sheet metal. The tool-workpiece interaction process is non-linear due to the large deformations of the sheet metal, which determine the plastic behaviour, as well as the evolutionary boundary conditions resulting from the contact between the tool and the sheet. Instead of lubricating the contact surface of the forming tool and the sheet metal, an innovative environmentally friendly method to reduce the coefficient of friction by vibrating the sheet has been proposed. The finite element method (FEM) allowed a virtual evaluation of the deformation parameters of the SPIF process in order to determine the destructive loads. The FEM was chosen as a deterministic numerical tool to evaluate the set of defect parameters induced by forming forces. The paper also proposes a method for predicting the formation force using an artificial neural network (ANN), assuming that such a model is generalized to implicit data. In this context, an empirical analysis of the implementation of the ANN technique is performed.

scholarly journals FEM simulation of waveguide flange manufacture by closed bulk forming

2018 ◽  
pp. 60-64
Author(s):  
A. A. Arkhipov ◽  
S. V. Lyubimskiy
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Technological Process ◽  
Strain State ◽  
Theoretical Study ◽  
Fem Simulation ◽  
The Finite Element Method ◽  
Stress Strain ◽  
Stress Strain State ◽  
Bulk Forming

The purpose of the study was to analyze the basic technological process of manufacturing waveguide flanges at PJSC “ALMAZ R&P Corp.” LEMZ Division. A method for optimizing the process has been proposed, and a theoretical study using the finite element method has been carried out. The stress-strain state of the forging of a complex shaped flange during its manufacture with closed bulk forming has been analyzed as well.

Finite Element Analysis of a Steel Bracket

2014 ◽  
Vol 1061-1062 ◽  
pp. 584-587
Author(s):  
Xiao Liang Chen ◽  
Zuan Tian ◽  
Yuan Ping Li
Keyword(s):  
Finite Element Method ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Mechanical Behavior ◽  
Sheet Metal ◽  
Theoretical Method ◽  
The Finite Element Method ◽  
Element Analysis ◽  
Stress And Deformation ◽  
Element Method

With the development of the society, sheet metal filing cabinets have become popular in the office. When filing cabinets store too many paper documents, the interlayer splints often fail because of the failure of the small brackets below. The stress and deformation of brackets were studied by the theoretical method and the finite element method. Results show some small machining shape defects have little influence on the mechanical behavior of brackets. The failure reason of small brackets is not the strength, but the instability.

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