scholarly journals Material Characterization for FEM Simulation of Sheet Metal Stamping Processes

2014 ◽  
Vol 6 ◽  
pp. 167147 ◽  
Author(s):  
Alejandro Quesada ◽  
Antonio Gauchia ◽  
Carolina Álvarez-Caldas ◽  
José Luis San Román
Keyword(s):  
Sheet Metal ◽  
Manufacturing Industry ◽  
Fem Simulation ◽  
Main Tool ◽  
Material Model ◽  
Experimental Results ◽  
Simulation Tools ◽  
Sheet Metal Parts ◽  
Simulation Results ◽  
Parameter Values

Sheet metal forming is an important technology in manufacturing, especially in the automotive industry. Today, engineering simulation tools based on the finite elements method are employed regularly in the design of stamping dies for sheet metal parts. However, a bad material model choice or the use of nonaccurate enough parameters can lead to imprecise simulation results. This work uses ANSYS LS-DYNA software to analyze several material models and the influence of their parameter values in FEM simulation results. The main tool to solve these problems is an application designed to assist die stamp designers. The program allows a procedure to be defined to obtain the values of the properties of an unknown material, which combines finite element simulations with real experimental results. Results obtained for the simulation of a real automotive part are analyzed and compared with the real experimental results. Parameters involved in each material model have been identified, and their influence in final results has been quantified. This is very useful to fit material properties in other simulations. This paper fulfils an identified need in the manufacturing industry. In fact, the proposed application is currently being used by a manufacturer of automotive components.

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.

scholarly journals Small Caliber Bulletproof Test of Warships’ Hulls

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3848
Author(s):  
Radosław Kiciński ◽  
Andrzej Kubit
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Boundary Conditions ◽  
Finite Element Method Simulation ◽  
Material Model ◽  
Experimental Results ◽  
Material Constants ◽  
Steel Core ◽  
Calculation Results ◽  
Simulation Results

The article presents the characteristics of 1.3964 steel and the results of firing a 7.62 mm projectile with a steel core. A simplified Johnson–Cook material model for steel and projectile was used. Then, a FEM (finite element method) simulation was prepared to calibrate the material constants and boundary conditions necessary to be used in simulations of the entire hull model. It was checked how projectile modeling affects the FEM calculation results. After obtaining the simulation results consistent with the experimental results, using the model of a modern minehunter, the resistance of the ship’s hull to penetration by a small-caliber projectile was tested.

Prediction of Life of Compound Die Using Artificial Neural Network (ANN)

2014 ◽  
Vol 622-623 ◽  
pp. 664-671 ◽  
Author(s):  
Sachin Kashid ◽  
Shailendra Kumar
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Sheet Metal ◽  
Research Work ◽  
Fem Simulation ◽  
Fem Analysis ◽  
Ann Model ◽  
Sheet Metal Parts ◽  
Artificial Neural ◽  
Artificial Neural Network Ann

Prediction of life of compound die is an important activity usually carried out by highly experienced die designers in sheet metal industries. In this paper, research work involved in the prediction of life of compound die using artificial neural network (ANN) is presented. The parameters affecting life of compound die are investigated through FEM analysis and the critical simulation values are determined. Thereafter, an ANN model is developed using MATLAB. This ANN model is trained from FEM simulation results. The proposed ANN model is tested successfully on different compound dies designed for manufacturing sheet metal parts. A sample run of the proposed ANN model is also demonstrated in this paper.

Forming Stability Analysis of Surface Flexible Rolling

2013 ◽  
Vol 798-799 ◽  
pp. 267-271
Author(s):  
Ren Jun Li ◽  
Ming Zhe Li ◽  
Zhong Yi Cai
Keyword(s):  
Numerical Simulation ◽  
Stability Analysis ◽  
Sheet Metal ◽  
Three Dimensional ◽  
Continuous Manufacturing ◽  
Forming Process ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Flexible Rolling ◽  
Simulation Results

Surface flexible rolling method, using two integral working rolls as the forming tool, can achieve fast, flexible and continuous manufacturing of three-dimensional sheet metal parts. This paper introduces the basic principle of surface flexible rolling and discusses the numerical simulation results when the working rolls are bended as circular arcs. The stability indicates the forming effect to some extent and the flow type of the metal can be deduced from stability analysis. To integrate and analyze the simulation results by means of reverse engineering. The analysis results show that the forming process is stable and the effect of surface flexible rolling is fine. It also indicates that inhomogeneous deformation and accumulation occurs during the process. The numerical simulation and experimental results demonstrate that the surface flexible rolling is a feasible and effective way to form three-dimensional sheet metal parts.

scholarly journals Numerical and Experimental Results on Charpy Tests for Blends Polypropylene + Polyamide + Ethylene Propylene Diene Monomer (PP+PA+EDPM)

2020 ◽  
Author(s):  
Catalin Pirvu ◽  
Andreea Elena Musteata ◽  
George Ghiocel Ojoc ◽  
Lorena Deleanu
Keyword(s):  
Equivalent Plastic Strain ◽  
Material Model ◽  
Element Model ◽  
Tensile Tests ◽  
Experimental Results ◽  
Low Velocity ◽  
Sem Images ◽  
Charpy Test ◽  
Simulation Results ◽  
The Impact

This paper presents results from numerical and experimental investigation on Charpy tests in order to point out failure mechanisms and to evaluate new polymeric blends PP+PA6+EPDM. Charpy tests were done for initial velocity of the impactor of 0.96 m/s and its mass of 3.219 kg and these data were also introduced in the finite element model. The proposed model take into account the system of four balls, including support and the ring of fixing the three balls and it has a finer discretization of the impact area to highlight the mechanisms of failure and their development in time. The constitutive models for four materials (polypropylene with 1% Kritilen, two blends PP+PA6+EPDM and a blend PA6+EPDM) were derived from tensile tests. Running simulations for each constitutive model of material makes possible to differentiate the destruction mechanisms according to the material introduced in the simulation, including the initiation and the development of the crack(s), based on equivalent plastic strain at break (EPS) for each material. The validation of the model and the simulation results was done qualitatively, analysing the shape of broken surfaces and comparing them to SEM images and quantitatively by comparing the impact duration, energy absorbed by the sample, the value of maximum force during impact. The duration of the destruction of the specimen is longer than the actual one, explainable by the fact that the material model does not take into account the influence of the material deformation speed in Charpy test, the model being designed with the help of tests done at 0.016 m/s (1000 mm/min) (maximum strain rate for the tensile tests). Experimental results are encouraging for recommending the blends 20% PP+42% PA6+28% EPDM and 60% PA6+ 40%EPDM as materials for impact protection at low velocity (1m/s). Simulation results are closer to the experimental ones for the more brittle tested materials (with less content of PA6 and EPDM) and more distanced for the more ductile materials (with higher content of PA6 and EPDM).

scholarly journals Numerical and Experimental Results on Charpy Tests for Blends Polypropylene + Polyamide + Ethylene Propylene Diene Monomer (PP + PA + EPDM)

Materials ◽  
2020 ◽  
Vol 13 (24) ◽  
pp. 5837
Author(s):  
Cătălin Pîrvu ◽  
Andreea Elena Musteată ◽  
George Ghiocel Ojoc ◽  
Lorena Deleanu
Keyword(s):  
Equivalent Plastic Strain ◽  
Material Model ◽  
Element Model ◽  
Tensile Tests ◽  
Experimental Results ◽  
Low Velocity ◽  
Sem Images ◽  
Charpy Test ◽  
Simulation Results ◽  
The Impact

This paper presents results from numerical and experimental investigation on Charpy tests in order to point out failure mechanisms and to evaluate new polymeric blends PP + PA6 + EPDM. Charpy tests were done for initial velocity of the impactor of 0.96 m/s and its mass of 3.219 kg and these data were also introduced in the finite element model. The proposed model takes into account the system of four balls, including support and the ring of fixing the three balls and it has a finer discretization of the impact area to highlight the mechanisms of failure and their development in time. The constitutive models for four materials (polypropylene with 1% Kritilen, two blends PP + PA6 + EPDM and a blend PA6 + EPDM) were derived from tensile tests. Running simulations for each constitutive model of material makes possible to differentiate the destruction mechanisms according to the material introduced in the simulation, including the initiation and the development of the crack(s), based on equivalent plastic strain at break (EPS) for each material. The validation of the model and the simulation results were done qualitatively, analyzing the shape of broken surfaces and comparing them to SEM images and quantitatively by comparing the impact duration, energy absorbed by the sample, the value of maximum force during impact. The duration of the destruction of the specimen is longer than the actual one, explainable by the fact that the material model does not take into account the influence of the material deformation speed in Charpy test, the model being designed with the help of tests done at 0.016 m/s (1000 mm/min) (maximum strain rate for the tensile tests). Experimental results are encouraging for recommending the blends 20% PP + 42% PA6 + 28% EPDM and 60% PA6 + 40% EPDM as materials for impact protection at low velocity (1 m/s). Simulation results are closer to the experimental ones for the more brittle tested materials (with less content of PA6 and EPDM) and more distanced for the more ductile materials (with higher content of PA6 and EPDM).

Ultraprecision Glass Molding Press for Microgrooves with Different Pitch Sizes

2013 ◽  
Vol 7 (6) ◽  
pp. 678-685 ◽  
Author(s):  
Ryuichi Kobayashi ◽  
◽  
Tianfeng Zhou ◽  
Keita Shimada ◽  
Masayoshi Mizutani ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Glass Surface ◽  
Fem Simulation ◽  
Experimental Results ◽  
Experimental Conditions ◽  
Glass Molding ◽  
Periodic Microstructures ◽  
Simulation Results ◽  
Efficient Manufacturing

Glass molding press is an efficient manufacturing technology to fabricate microstructures on glass. To optimize the experimental conditions for precision replication of periodic microstructures with different pitch sizes, Finite Element Method (FEM) simulation and experiments were carried out to study the glass molding press process. First, the effects of the change in pitch size on stress and geometrical replicating accuracy were evaluated. Thereafter, glass molding experiments were carried out to form microstructures on the glass surface, and the molded microstructures were measured. By comparing the simulation results with experimental results, the FEM simulation was experimentally verified, and the optimal machining conditions were obtained and discussed.

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