Environmental and Economic Evaluation of the Sheet Metal Stamping Process Using Alternative Lubricants

2019 ◽  
Author(s):  
Daniele Landi ◽  
Michele Germani ◽  
Marco Mandolini ◽  
Marco Marconi ◽  
Claudio Favi
Keyword(s):  
Economic Evaluation ◽  
Sheet Metal ◽  
Electric Energy ◽  
Manufacturing Cost ◽  
Sheet Metal Stamping ◽  
Electric Energy Consumption ◽  
Metal Stamping ◽  
Almost All ◽  
Sheet Metal Component

Abstract Sheet metal forming of tribologically difficult materials (e.g. stainless steel) or forming in tribologically difficult conditions (e.g. ironing, punching, deep drawing) require the use of environmentally hazardous lubricants, such as chlorinated paraffin oils in order to avoid galling. The present paper describes an environmental and economic evaluation of two alternative sheet metal stamping processes. The forming of a sheet metal component for boiler burners has been taken as case study for the analyses. In particular, two different lubricants (standard mineral versus polymer matrix-based lubricant) have been tested and compared. However, the differences among the two processes involves not only the lubrication phase, but also the electric energy consumption during the stamping and degreasing, as well as the typology of solvent (perchloroethylene versus water). Results obtained with the economic analysis show that the use of the alternative lubricant leads to a 16% reduction of the total manufacturing cost, mainly due to the optimization of the degreasing. Concerning environmental results, instead, no relevant differences can be observed for almost all the considered impact categories (ReCiPe midpoint and endpoint), since the optimized phases are not the most critical ones.

Optimisation of Die Radius Geometry in Sheet Metal Stamping

2011 ◽  
Vol 337 ◽  
pp. 350-353 ◽  
Author(s):  
Xuan Zhi Wang ◽  
S.H. Masood
Keyword(s):  
Tool Wear ◽  
Sheet Metal ◽  
High Strength Steels ◽  
High Strength ◽  
Sheet Metal Stamping ◽  
Advanced High Strength Steels ◽  
Metal Stamping ◽  
Contact Pressures ◽  
Abaqus Software

Advanced high strength steels (AHSS) are increasingly utilised in sheet metal stamping in the automotive manufacture. In comparison with conventional steels, AHSS stampings produce higher contact pressures at the interface between the tool-workpiece interface, leading to more severe wear conditions, particularly at the draw die radius. To minimise tool wear using this approach it would be necessary to optimise the shape for a particular combination of circular and high elliptical profiles. This paper presents a methodology to optimise a die radius profile. For this, a specialised software routine is developed and compiled for optimisation of die radius profiles to minimise or achieve uniform contact pressure (wear distribution) using Python computer programming language supported by Abaqus software. A detailed algorithm for the optimisation is explained. A case study based on the algorithm is also discussed.

scholarly journals МОДЕЛЮВАННЯ ПРОЦЕСІВ ВИРУБКИ-ПРОБИВКИ ПЕРЕДАВАЛЬНИМИ СЕРЕДОВИЩАМИ

2021 ◽  
pp. 104-111
Author(s):  
А. Н. Застела ◽  
В. В. Борисевич
Keyword(s):  
Sheet Metal ◽  
Complex Geometry ◽  
Thin Sheet ◽  
Manufacturing Cost ◽  
Forming Process ◽  
Sheet Metal Stamping ◽  
Metal Stamping ◽  
Thin Sheet Metal

During improvement of the quality of products and reducing its cost, sheet metal stamping production, being the basis for the aerospace industry, should more intensively introduce modern production technologies, especially design. There are a large number of factors influencing the stamping process (especially parts with complex geometry), more comprehensive consideration of which would allow to optimize such processes, thereby reducing the manufacturing cost and improving the  quality. Currently the processes of forming and separation of complex parts by  of an elastic pad are of interest from the point of view of optimization and the final determination of the nature of the behavior of the material. This includes the refinement of such parameters as the maximum permissible thinning, the strength of the die. Clarification of these and other parameters will significantly reduce energy required. Determination of these and other parameters of sheet metal stamping is possible due to application of the modern analysis methods. For numerical studies in the sheet stamping production, the variational method or FEM is the most suitable. Computer modeling makes it possible to investigate the behavior of the material, the kinematics of the workpiece movement during forming process, select the correct loading scheme for the workpiece, and also makes it possible to consider several options for the location of the workpiece in the die, which is very important for  stamping thin sheet metal blanks. It provides a significant reduction of the time and costs for carrying out natural experiments, and decrease of technological preproduction preparation of sheet metal stamping. The development of a mathematical model based on the FEM makes it possible to determine not only the required parameters of the process, but also to consider the forming process during its certain stages, to determine the stress-strain state, indicating at the same time the problem zones of excessive thinning, loss of stability, the need to apply a die with a back pressure for cutting of thin sheet metal blanks. It allows to evaluate the quality of a ready product according to the calculated parameters, to use the results obtained for the design of elastic pad

scholarly journals Analysis of the risk of galling in sheet metal stamping dies with drawbeads

2020 ◽  
Vol 234 (9) ◽  
pp. 1207-1214
Author(s):  
Marcel Moghadam ◽  
Chris Valentin Nielsen ◽  
Niels Bay
Keyword(s):  
Sheet Metal ◽  
Metal Flow ◽  
Three Dimensional ◽  
Interface Temperature ◽  
Industrial Case Study ◽  
Sheet Metal Stamping ◽  
Stamping Dies ◽  
Production Platform ◽  
Metal Stamping

Sheet metal stamping of complex geometries normally involves the use of drawbeads to control the metal flow in the forming die. Drawbeads are, however, often the most tribologically severe part of the stamping dies. Selection of a suitable tribosystem for this type of forming operation depends on parameters such as local contact pressures, sliding speed, tool/workpiece interface temperature, tool and workpiece materials, and surface topographies. Furthermore, it depends on the required tool life and acceptable maintenance costs. This study demonstrates a methodology for offline evaluation of tribosystem applicability for a specific production platform for stamping of a three-dimensional component using a forming die with drawbeads. Based on an industrial case study, this work combines experimental and numerical analyses of the risk of galling in the different regions of an industrial forming die.

The Structure and Mechanical Properties of Aluminum Cellular Metal With Periodic Cubic Cells

2016 ◽  
Author(s):  
Xiaobing Dang ◽  
Ruxu Du ◽  
Kai He ◽  
Qiyang Zuo
Keyword(s):  
Mechanical Properties ◽  
Relative Density ◽  
Sheet Metal ◽  
Light Weight ◽  
Practical Applications ◽  
Sheet Metal Stamping ◽  
High Stiffness ◽  
The Past ◽  
Cellular Metal ◽  
Metal Stamping

As a light-weight material with high stiffness and strength, cellular metal has attracted a lot of attentions in the past two decades. In this paper, the structure and mechanical properties of aluminum cellular metal with periodic cubic cells are studied. The aluminum cellular metal is fabricated by sheet metal stamping and simple adhesion. Two sizes of specimens with cell sizes of 3mm and 5mm are fabricated. Their relative density and mechanical properties are tested by means of experiments. The results show that the cubic-cell cellular metal has high and predictable strength and hence, can be used for many practical applications.

An Engineering Approach to Improve the Stamping Robustness of High Strength Steels

2009 ◽  
Vol 131 (6) ◽  
Author(s):  
Wu-rong Wang ◽  
Bo Hou ◽  
Zhong-qin Lin ◽  
Z. Cedric Xia
Keyword(s):  
Sheet Metal ◽  
Weight Ratio ◽  
High Strength Steels ◽  
High Strength ◽  
Process Variations ◽  
Optimal Process ◽  
Sheet Metal Stamping ◽  
The Monte Carlo Method ◽  
Metal Stamping ◽  
Metal Properties

High strength steels (HSSs) are one of the light-weight sheet metals well suited for reducing vehicle weight due to their higher strength-to-weight ratio. However, HSS tend to have bigger variations in their mechanical properties due to more complex rolling techniques involved in the steel-making process. Such uncertainties, when combined with variations in the process parameters such as friction and blank holder force, pose a significant challenge in maintaining the robustness of HSS sheet metal stamping. The paper presents a systematic and robust approach, combining the power of the finite element method and stochastic statistics to decrease the sensitivity of HSS stamping in the presence of above-mentioned uncertainties. First, the statistical distribution of sheet metal properties of selected HSS is characterized from a material sampling database. Then a separate interval adaptive response surface methodology (RSM) is applied in modeling sheet metal stamping. The new method significantly improves the model accuracy when compared with the conventional RSM within a single interval. Finally, the Monte Carlo method is employed to simulate the stochastic response of material/process variations to stamping quality and to provide optimal process parameter designs to reduce the sensitivity of these effects. The experiment with the obtained optimal process design demonstrates the improvements of stamping robustness using small-batch experiments.

scholarly journals Water Efficiency Management Strategies in Electric Engineering Generation Industries: an Epilogue

2019 ◽  
Vol 9 (1) ◽  
pp. 840-842
Keyword(s):  
Andhra Pradesh ◽  
Management Strategies ◽  
Electric Energy ◽  
Research Paper ◽  
Water Efficiency ◽  
Electric Energy Consumption ◽  
Study Approach ◽  
Electric Engineering ◽  
Electric Generation

The impending jeopardies relating to dearth of water in performing the techno economic activity of production of electricity in power industries ushered gainful insights for this research paper for pursuing to reckon and quantify the renewable electric energy consumption of water by gauging at the foot prints. This research paper presses the need of the hour to persistently stimulate the electric generation industries to integrate the multidimensional anomalies of seasonal changes of monsoonal fresh water in the arena of Environmental micro and macro climate strategies. Taking cue of electric energy water sequential linkages using water foot printing technology this paper empirically estimated that, minimum water foot print was recorded in selected biomass and natural gas based electricity producing industries to yield 1000 kilowatt of electricity vis-à-vis selected Hydel power station, which has voracious appetite. This research has been performed with a field level investigation of assessing the magnitude of water scarcity by performing a documentation of exemplary investigative case study approach in selected regions of Andhra Pradesh.

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