Abstract: 3-roller conical bending process is widely used in the
industries for manufacturing of conical sections and shells. It
involves static as well dynamic bending stages. Analytical models for
prediction of bending force during static as well as dynamic bending
stage are available in the literature. In this paper bending forces
required for static bending stage and dynamic bending stages have
been compared using the analytical models. It is concluded that force
required for dynamic bending is very less as compared to the bending
force required during the static bending stage.
Abstract: Tailor Welded Blanks (TWB) are utilized in automotive industries widely because of their advantage of weight and cost reduction and maintaining required strength and structural integrity. TWB consist of two or more sheet having dissimilar or similar material and thickness; welded together to form a single sheet before forming it to desired shape. Forming of the tailor welded blank is affected by ratio of thickness of blanks, ratio of their strength, etc. mainly due to in-homogeneity of material. In the present work the relative effect of these parameters on weld line movement is studied during deep drawing of TWB using FE simulation using HYPERWORKS. The simulation is validated with results from the literature. Simulations were than performed based on Taguchi orthogonal array followed by the ANOVA analysis to determine the significance of these parameters on forming of TWB.
Abstract: Carbon steel is used in boilers, pressure vessels, heat
exchangers, piping, structural elements and other moderatetemperature
service systems in which good strength and ductility are
desired. ASME Boiler and Pressure Vessel Code, Section II Part A
(2004) provides specifications of ferrous materials for construction of
pressure equipment, covering wide range of mechanical properties
including high strength materials for power plants application.
However, increased level of springback is one of the major problems
in fabricating components of high strength steel using bending.
Presented work discuss the springback simulations for five different
steels (i.e. SA-36, SA-299, SA-515 grade 70, SA-612 and SA-724
grade B) using finite element analysis of air V-bending. Analytical
springback simulations of hypothetical layered materials are
presented. Result shows that; (i) combination of the material property
parameters controls the springback, (ii) layer of the high ductility
steel on the high strength steel greatly suppresses the springback.
Abstract: Bendability is constrained by maximum top roller
load imparting capacity of the machine. Maximum load is
encountered during the edge pre-bending stage of roller bending.
Capacity of 3-roller plate bending machine is specified by
maximum thickness and minimum shell diameter combinations that
can be pre-bend for given plate material of maximum width.
Commercially available plate width or width of the plate that can be
accommodated on machine decides the maximum rolling width.
Original equipment manufacturers (OEM) provide the machine
capacity chart based on reference material considering perfectly
plastic material model. Reported work shows the bendability analysis
of heavy duty 3-roller plate bending machine. The input variables for
the industry are plate thickness, shell diameter and material property
parameters, as it is fixed by the design. Analytical models of
equivalent thickness, equivalent width and maximum width based on
power law material model were derived to study the bendability.
Equation of maximum width provides bendability for designed
configuration i.e. material property, shell diameter and thickness
combinations within the machine limitations. Equivalent thicknesses
based on perfectly plastic and power law material model were
compared for four different materials grades of C-Mn steel in order
to predict the bend-ability. Effect of top roller offset on the
bendability at maximum top roller load imparting capacity is
reported.
Abstract: Air bending is one of the important metal forming
processes, because of its simplicity and large field application.
Accuracy of analytical and empirical models reported for the analysis
of bending processes is governed by simplifying assumption and do
not consider the effect of dynamic parameters. Number of researches
is reported on the finite element analysis (FEA) of V-bending, Ubending,
and air V-bending processes. FEA of bending is found to be
very sensitive to many physical and numerical parameters. FE
models must be computationally efficient for practical use. Reported
work shows the 3D FEA of air bending process using Hyperform LSDYNA
and its comparison with, published 3D FEA results of air
bending in Ansys LS-DYNA and experimental results. Observing the
planer symmetry and based on the assumption of plane strain
condition, air bending problem was modeled in 2D with symmetric
boundary condition in width. Stress-strain results of 2D FEA were
compared with 3D FEA results and experiments. Simplification of
air bending problem from 3D to 2D resulted into tremendous
reduction in the solution time with only marginal effect on stressstrain
results. FE model simplification by studying the problem
symmetry is more efficient and practical approach for solution of
more complex large dimensions slow forming processes.