Abstract: Steel Metal Shear Wall is one of the most common and widely used energy dissipation systems in structures, which is used today as a damping system due to the increase in the construction of metal structures. In the present study, the shear wall of the steel plate with dimensions of 5×3 m and thickness of 0.024 m was modeled with 2 floors of total height from the base level with finite element method in Abaqus software. The loading is done as a concentrated load at the upper point of the shear wall on the second floor based on step type buckle. The mesh in the model is applied in two directions of length and width of the shear wall, equal to 0.02 and 0.033, respectively, and the mesh in the models is of sweep type. Finally, it was found that the steel plate shear wall with cavity (CSPSW) compared to the SPSW model, S (Mises), Smax (In-Plane Principal), Smax (In-Plane Principal-ABS), Smax (Min Principal) increased by 53%, 70%, 68% and 43%, respectively. The presence of cavities has led to an increase in the estimated stresses, but their presence has caused critical stresses and critical deformations created to be removed from the inner surface of the shear wall and transferred to the desired sections (regular cavities) which can be suggested as a solution in seismic design and improvement of the structure to transfer possible damage during the earthquake and storm to the desired and pre-designed location in the structure.
Abstract: In this study, process parameters like punch angle, die opening, grain direction, and pre-bend condition of the strip for deep draw of high strength low alloy steel HSLA 420 are investigated. The finite element method (FEM) in association with the Taguchi and the analysis of variance (ANOVA) techniques are carried out to investigate the degree of importance of process parameters in V-bending process for HSLA 420&ST12 grade material. From results, it is observed that punch angle had a major influence on the spring-back. Die opening also showed very significant role on spring back. On the other hand, it is revealed that grain direction had the least impact on spring back; however, if strip from flat sheet is taken, then it is less prone to spring back as compared to the strip from sheet metal coil. HyperForm software is used for FEM simulation and experiments are designed using Taguchi method. Percentage contribution of the parameters is obtained through the ANOVA techniques.
Abstract: Sheet metal processing is automated, but the step from product models to the production machine control still requires human intervention. This may cause time consuming bottlenecks in the production process and increase the risk of human errors. In this paper we present a system, which automatically recognizes features from the CAD-model of the sheet metal product. By using these features, the system produces a complete model of the particular sheet metal product. Then the model is used as an input for the sheet metal processing machine. Currently the system is implemented, capable to recognize more than 11 of the most common sheet metal structural features, and the procedure is fully automated. This provides remarkable savings in the production time, and protects against the human errors. This paper presents the developed system architecture, applied algorithms and system software implementation and testing.
Abstract: Multi-point forming (MPF) and asymmetric incremental forming (ISF) are two flexible processes for sheet metal manufacturing. To take advantages of these two techniques, a hybrid process has been developed: The Multipoint Incremental Forming (MPIF). This process accumulates at once the advantages of each of these last mentioned forming techniques, which makes it a very interesting and particularly an efficient process for single, small, and medium series production. In this paper, an experimental and a numerical investigation of this technique are presented. To highlight the flexibility of this process and its capacity to manufacture standard and complex shapes, several pieces were produced by using MPIF. The forming experiments are performed on a 3-axis CNC machine. Moreover, a numerical model of the MPIF process has been implemented in ABAQUS and the analysis showed a good agreement with experimental results in terms of deformed shape. Furthermore, the use of an elastomeric interpolator allows avoiding classical local defaults like dimples, which are generally caused by the asymmetric contact and also improves the distribution of residual strain. Future works will apply this approach to other alloys used in aeronautic or automotive applications.
Abstract: Lightweight construction became more and more important over the last decades in several applications, e.g. in the automotive or aircraft sector. This is the result of economic and ecological constraints on the one hand and increasing safety and comfort requirements on the other hand. In the field of lightweight design, different approaches are used due to specific requirements towards the technical systems. The use of endless carbon fiber reinforced plastics (CFRP) offers the largest weight saving potential of sometimes more than 50% compared to conventional metal-constructions. However, there are very limited industrial applications because of the cost-intensive manufacturing of the fibers and production technologies. Other disadvantages of pure CFRP-structures affect the quality control or the damage resistance. One approach to meet these challenges is hybrid materials. This means CFRP and sheet metal are combined on a material level. Therefore, new opportunities for innovative process routes are realizable. Hybrid lightweight design results in lower costs due to an optimized material utilization and the possibility to integrate the structures in already existing production processes of automobile manufacturers. In recent and current research, the advantages of two-layered hybrid materials have been pointed out, i.e. the possibility to realize structures with tailored mechanical properties or to divide the curing cycle of the epoxy resin into two steps. Current research work at the Chair for Automotive Lightweight Design (LiA) at the Paderborn University focusses on production processes for fiber-metal-laminates. The aim of this work is the development and qualification of a large-scale production process for high-performance fiber-metal-laminates (FML) for industrial applications in the automotive or aircraft sector. Therefore, the prepreg-press-technology is used, in which pre-impregnated carbon fibers and sheet metals are formed and cured in a closed, heated mold. The investigations focus e.g. on the realization of short process chains and cycle times, on the reduction of time-consuming manual process steps, and the reduction of material costs. This paper gives an overview over the considerable steps of the production process in the beginning. Afterwards experimental results are discussed. This part concentrates on the influence of different process parameters on the mechanical properties, the laminate quality and the identification of process limits. Concluding the advantages of this technology compared to conventional FML-production-processes and other lightweight design approaches are carried out.
Abstract: Sheet-metal parts have been widely applied in electronics, communication and mechanical industries in recent decades; but the advancement in sheet-metal part design and manufacturing is still behind in comparison with the increasing importance of sheet-metal parts in modern industry. This paper presents a methodology for automatic extraction of some common 2D internal sheet metal features. The features used in this study are taken from Unipunch ™ catalogue. The extraction process starts with the data extraction from STEP file using an object oriented approach and with the application of suitable algorithms and rules, all features contained in the catalogue are automatically extracted. Since the extracted features include geometry and engineering information, they will be effective for downstream application such as feature rebuilding and process planning.
Abstract: Ultrasonic metal welding has been the subject of ongoing research and development, most recently concentrating on metal joining in miniature devices, for example to allow solder-free wire bonding. As well as at the small scale, there are also opportunities to research the joining of thicker sheet metals and to widen the range of similar and dissimilar materials that can be successfully joined using this technology. This study presents the design, characterisation and test of a lateral-drive ultrasonic metal spot welding device. The ultrasonic metal spot welding horn is modelled using finite element analysis (FEA) and its vibration behaviour is characterised experimentally to ensure ultrasonic energy is delivered effectively to the weld coupon. The welding stack and fixtures are then designed and mounted on a test machine to allow a series of experiments to be conducted for various welding and ultrasonic parameters. Weld strength is subsequently analysed using tensile-shear tests. The results show how the weld strength is particularly sensitive to the combination of clamping force and ultrasonic vibration amplitude of the welding tip, but there are optimal combinations of these and also limits that must be clearly identified.
Abstract: In this work, the plastic behaviour of cold-rolled zinc
coated dual-phase steel sheets DP600 and DP800 grades is firstly
investigated with the help of uniaxial, hydraulic bulge and Forming
Limit Curve (FLC) tests. The uniaxial tensile tests were performed in
three angular orientations with respect to the rolling direction to
evaluate the strain-hardening and plastic anisotropy. True stressstrain
curves at large strains were determined from hydraulic bulge
testing and fitted to a work-hardening equation. The limit strains are
defined at both localized necking and fracture conditions according to
Nakajima’s hemispherical punch procedure. Also, an elasto-plastic
localization model is proposed in order to predict strain and stress
based forming limit curves. The investigated dual-phase sheets
showed a good formability in the biaxial stretching and drawing FLC
regions. For both DP600 and DP800 sheets, the corresponding
numerical predictions overestimated and underestimated the
experimental limit strains in the biaxial stretching and drawing FLC
regions, respectively. This can be attributed to the restricted failure
necking condition adopted in the numerical model, which is not
suitable to describe the tensile and shear fracture mechanisms in
advanced high strength steels under equibiaxial and biaxial stretching
conditions.
Abstract: There is not much effective guideline on development of design parameters selection on spring back for advanced high strength steel sheet metal in U-channel process during cold forming process. This paper presents the development of predictive model for spring back in U-channel process on advanced high strength steel sheet employing Response Surface Methodology (RSM). The experimental was performed on dual phase steel sheet, DP590 in Uchannel forming process while design of experiment (DoE) approach was used to investigates the effects of four factors namely blank holder force (BHF), clearance (C) and punch travel (Tp) and rolling direction (R) were used as input parameters using two level values by applying Full Factorial design (24 ). From a statistical analysis of variant (ANOVA), result showed that blank holder force (BHF), clearance (C) and punch travel (Tp) displayed significant effect on spring back of flange angle (β2 ) and wall opening angle (β1 ), while rolling direction (R) factor is insignificant. The significant parameters are optimized in order to reduce the spring back behavior using Central Composite Design (CCD) in RSM and the optimum parameters were determined. A regression model for spring back was developed. The effect of individual parameters and their response was also evaluated. The results obtained from optimum model are in agreement with the experimental values.
Abstract: Laser beam welding of dissimilar sheet metal
combinations such as Ti/Al, SS/Al and Cu/Al are increasingly
demanded due to high energy densities with less fusion and heat
affected zones. A good weld joint strength involves combinations of
dissimilar metals and the formation of solid solution in the weld pool.
Many metal pairs suffer from significant intermetallic phase
formation during welding which greatly reduces their strength. The
three different sheet metal mentioned above is critically reviewed and
phase diagram for the combinations are given. The aim of this study
is to develop an efficient metal combinations and the influence on
their interfacial characteristics. For that the following parameters
such as weld geometry, residual distortion, micro hardness,
microstructure and mechanical properties are analyzed
systematically.
Abstract: In sheet metal forming process, raw material
mechanical properties are important parameters. This paper is to
compare the wall’s incline angle or formability of SS 400 steel and
SUS 304 stainless steel in single point incremental forming. The two
materials are ferrous base alloyed, which have the different unit cell,
mechanical property and chemical composition. They were forming
into cone shape specimens having 100 mm diameter with different
wall’s incline angle: 90o, 75o and 60o. The investigation was
continued until the specimens formed surface facture. The
experimental result showed that the smaller the wall incline angle
higher the formability with the both materials. The formability limit
of the ferrous base alloy was approx. 60o wall’s incline angle. By
nature, SS 400 has higher formability than SUS 304. This result can
be used as the initial data in designing the single point incremental
forming parts.
Abstract: This paper aims at experimental and numerical investigation of springback behavior of sheet metals during L-bending process with emphasis on Stribeck-type friction modeling. The coefficient of friction in Stribeck curve depends on sliding velocity and contact pressure. The springback behavior of mild steel and aluminum alloy 6022-T4 sheets was studied experimentally and using numerical simulations with ABAQUS software with two types of friction model: Coulomb friction and Stribeck friction. The influence of forming speed on springback behavior was studied experimentally and numerically. The results showed that Stribeck-type friction model has better results in predicting springback in sheet metal forming. The FE prediction error for mild steel and 6022-T4 AA is 23.8%, 25.5% respectively, using Coulomb friction model and 11%, 13% respectively, using Stribeck friction model. These results show that Stribeck model is suitable for simulation of sheet metal forming especially at higher forming speed.
Abstract: The design of multi stage deep drawing processes requires the evaluation of many process parameters such as the intermediate die geometry, the blank shape, the sheet thickness, the blank holder force, friction, lubrication etc..These process parameters have to be determined for the optimum forming conditions before the process design. In general sheet metal forming may involve stretching drawing or various combinations of these basic modes of deformation. It is important to determine the influence of the process variables in the design of sheet metal working process. Especially, the punch and die corner for deep drawing will affect the formability. At the same time the prediction of sheet metals springback after deep drawing is an important issue to solve for the control of manufacturing processes. Nowadays, the importance of this problem increases because of the use of steel sheeting with high stress and also aluminum alloys.
The aim of this paper is to give a better understanding of the springback and its effect in various sheet metals forming process such as expansion and restreint deep drawing in the cup drawing process, by varying radius die, lubricant for two commercially available materials e.g. galvanized steel and Aluminum sheet. To achieve these goals experiments were carried out and compared with other results. The original of our purpose consist on tests which are ensured by adapting a U-type stretching-bending device on a tensile testing machine, where we studied and quantified the variation of the springback.
Abstract: Resistance spot welding (RSW) has been used widely to join sheet metals. It has been a challenge to get required weld quality in spot welding of dissimilar thickness materials. Weld parameters are not generally available in standards for thickness beyond 4mm. This paper presents the welding process design and parameter optimization of RSW used in joining of low carbon steel sheet of thickness 0.8 mm and metal strips of cross section 10 x 5mm for electrical motor applications. Taguchi quality design was adopted for weld current and time optimization using L9 orthogonal array. Optimum process parameters (current- 3.5kA and time- 10 cycles) were obtained from the Taguchi analysis and shear test results. Confirmation experiment result revealed that the weld quality was within acceptable interval. Further, numerical simulation of RSW process was carried out with selected weld parameters to quantify the temperature at faying surface and check for formation of appropriate nugget. The nugget geometry measured after peel test and predicted from numerical validation method were similar and in accordance with the standards.
Abstract: Oxyhydrogen is a mixture of Hydrogen (H2) and Oxygen (O2) gases. Detonative mixtures of oxyhydrogens with various combinations of these two gases were used in Gas Detonation Forming (GDF) to form sheets of mild steel. In die forming experiments, three types of conical dies with apex angles of 60, 90 and 120 degrees were used. Pressure of mixtures inside the chamber before detonation was varied from 3 Bar to 5 Bar to investigate the effect of pre-detonation pressure in the forming process. On each conical die, several experiments with different percentages of Hydrogen were carried out to determine the optimum gaseous mixture. According to our results the best forming process occurred when approximately 50-70%. Hydrogen was employed in the mixture. Furthermore, the experimental results were compared to the ones from FEM analysis. The FEM simulation results of thickness strain, hoop strain, thickness variation and deformed geometry are promising.
Abstract: Springback is a significant problem in the sheet metal
forming process. When the tools are released after the stage of
forming, the product springs out, because of the action of the internal
stresses. In many cases the deviation of form is too large and the
compensation of the springback is necessary. The precise prediction
of the springback of product is increasingly significant for the design
of the tools and for compensation because of the higher ratio of the
yield stress to the elastic modulus.
The main object in this paper was to study the effect of the
anisotropy on the springback for three directions of rolling: 0°, 45°
and 90°. At the same time, we highlighted the influence of three
different metallic materials: Aluminum, Steel and Galvanized steel.
The original of our purpose consist on tests which are ensured by
adapting a U-type stretching-bending device on a tensile testing
machine, where we studied and quantified the variation of the
springback according to the direction of rolling. We also showed the
role of lubrication in the reduction of the springback.
Moreover, in this work, we have studied important characteristics
in deep drawing process which is a springback. We have presented
defaults that are showed in this process and many parameters
influenced a springback.
Finally, our results works lead us to understand the influence of
grains orientation with different metallic materials on the springback
and drawing some conclusions how to concept deep drawing tools. In
addition, the conducted work represents a fundamental contribution
in the discussion the industry application.
Abstract: In this research, Forming Limit Diagrams for supertension
sheet metals which are using in automobile industry have
been obtained. The exerted strains to sheet metals have been
measured with four different methods and the errors of each method
have also been represented. These methods have been compared with
together and the most efficient and economic way of extracting of the
exerted strains to sheet metals has been introduced. In this paper total
error and uncertainty of FLD extraction procedures have been
derived. Determination of the measurement uncertainty in extracting
of FLD has a great importance in design and analysis of the sheet
metal forming process.
Abstract: To investigate the behavior of sheet metals during
forming tailor welded blanks (TWB) of various thickness made via
Co2 Laser welding are under consideration. These blanks are formed
used two different forming methods of rubber as well as the
conventional punch and die methods. The main research objective is
the effects of using a rubber die instead of a solid one the
displacement of the weld line and the press force needed for forming.
Specimens with thicknesses of 0.5, 0.6, 0.8 and 1mm are subjected to
Erichsen two dimensional tests and the resulted force for each case
are compared. This is followed by a theoretical and numerical study
of press force and weld line displacement. It is concluded that using
rubber pad forming (RPF) causes a reduction in weld line
displacement and an increase in the press force.
Abstract: Tailor-welded Blanks (TWBs) are tailor made for
different complex component designs by welding multiple metal
sheets with different thicknesses, shapes, coatings or strengths prior
to forming. In this study the Hemispherical Die Stretching (HDS) test
(out-of-plane stretching) of TWBs were simulated via
ABAQUS/Explicit to obtain the Forming Limit Diagrams (FLDs) of
Stainless steel (AISI 304) laser welded blanks with different
thicknesses. Two criteria were used to detect the start of necking to
determine the FLD for TWBs and parent sheet metals. These two
criteria are the second derivatives of the major and thickness strains
that are given from the strain history of simulation. In the other word,
in these criteria necking starts when the second derivative of
thickness or major strain reaches its maximum. With having the time
of onset necking, one can measure the major and minor strains at the
critical area and determine the forming limit curve.
Abstract: The plastic forming process of sheet plate takes an
important place in forming metals. The traditional techniques of tool
design for sheet forming operations used in industry are experimental
and expensive methods. Prediction of the forming results,
determination of the punching force, blank holder forces and the
thickness distribution of the sheet metal will decrease the production
cost and time of the material to be formed. In this paper, multi-stage
deep drawing simulation of an Industrial Part has been presented
with finite element method. The entire production steps with
additional operations such as intermediate annealing and springback
has been simulated by ABAQUS software under axisymmetric
conditions. The simulation results such as sheet thickness
distribution, Punch force and residual stresses have been extracted in
any stages and sheet thickness distribution was compared with
experimental results. It was found through comparison of results, the
FE model have proven to be in close agreement with those of
experiment.