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

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

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.

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

Conventional multi-step extrusion processes with solid billet are examined by the rigid-plastic finite element method in order to provide criteria for new process sequence for hollow parts. Two examples are taken for the analyses such as the current three-stage cold extrusion process for a hollow flange part and five-stage process for manufacturing an axle housing. Based on the results of simulation of the current three-stage and five-stage manufacturing processes, new design strategy for improving the process sequences is developed simply by replacing the initial billet from solid to hollow one. The developed new process sequences are applied for simulation by FEM and they are compared with the existing processes to confirm the usefulness of new process sequences with hollow initial billets. The results of simulation show that the newly proposed process sequences with hollow billet instead of solid one are more economical way to manufacture required parts, respectively.

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

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.