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: 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: 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: 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: In a metal forming process, the friction between the
material and the tools influences the process by modifying the stress
distribution of the workpiece. This frictional behaviour is often taken
into account by using a constant coefficient of friction in the finite
element simulations of sheet metal forming processes. However,
friction coefficient varies in time and space with many parameters.
The Stribeck friction model is investigated in this study to predict
springback behaviour of AA6061-T4 sheets during V-bending
process. The coefficient of friction in Stribeck curve depends on
sliding velocity and contact pressure. The plane-strain bending
process is simulated in ABAQUS/Standard. We compared the
computed punch load-stroke curves and springback related to the
constant coefficient of friction with the defined friction model. The
results clearly showed that the new friction model provides better
agreement between experiments and results of numerical simulations.
The influence of friction models on stress distribution in the
workpiece is also studied numerically
Abstract: Intelligent deep-drawing is an instrumental research field in sheet metal forming. A set of 28 different experimental data have been employed in this paper, investigating the roles of die radius, punch radius, friction coefficients and drawing ratios for axisymmetric workpieces deep drawing. This paper focuses an evolutionary neural network, specifically, error back propagation in collaboration with genetic algorithm. The neural network encompasses a number of different functional nodes defined through the established principles. The input parameters, i.e., punch radii, die radii, friction coefficients and drawing ratios are set to the network; thereafter, the material outputs at two critical points are accurately calculated. The output of the network is used to establish the best parameters leading to the most uniform thickness in the product via the genetic algorithm. This research achieved satisfactory results based on demonstration of neural networks.
Abstract: A lot of research made during these last 15 years
showed that the quantification of the springback has a significant role
in the industry of sheet metal forming. These studies were made with
the objective of finding techniques and methods to minimize or
completely avoid this permanent physical variation. Moreover, the
use of steel and aluminum alloys in the car industry and aviation
poses every day the problem of the springback. The determination in
advance of the quantity of the springback allows consequently the
design and manufacture of the tool. The aim of this paper is to study
experimentally the influence of the blank holder force BHF and the
radius of curvature of the die on the springback and their influence on
the strain in various zone of specimen.
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 displacement.