Search results for: forming tools

Authors: Jiwoo Park, Junseok Yoon, Jeong Kim, Beomsoo Kang

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Multi-Point Stretch Forming (MPSF) process is suitable for flexible manufacturing, and it has several advantages including that it could be applied to various forming such as sheet metal forming, single curved surface forming and double curved one. In this study, a systematic numerical simulation was carried out for atypical double curved surface forming using the multiple die stretch forming process. In this simulation, urethane pads were defined based on hyper-elastic material model as a cushion for the smooth forming surface. The deformation behaviour on elastic recovery was also investigated to consider the exact result after the last forming process, and then the experiment was also carried out to confirm the formability of this forming process. By comparing the simulation and experiment results, the suitability of the multiple die stretch forming process for the atypical double curved surface was verified. Consequently, it is confirmed that the multi-point stretch forming process has the capability and feasibility of being used to manufacture the double curved surfaces of sheet metal.

Keywords: multi-point stretch forming, double curved surface, numerical simulation, manufacturing

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Authors: Michal Brazda, Miroslav Urbanek, Martina Koukolikova

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This work focuses on the development of functional surfaces and edges for cutting and forming tools created through the Directed Energy Deposition (DED) technology. In the context of growing challenges in modern engineering, additive technologies, especially DED, present an innovative approach to manufacturing tools for forming and cutting. One of the key features of DED is its ability to precisely and efficiently deposit Fully dense metals from powder feedstock, enabling the creation of complex geometries and optimized designs. Gradually, it becomes an increasingly attractive choice for tool production due to its ability to achieve high precision while simultaneously minimizing waste and material costs. Tools created using DED technology gain significant durability through the utilization of high-performance materials such as nickel alloys and tool steels. For high-temperature applications, Nimonic 80A alloy is applied, while for cold applications, M2 tool steel is used. The addition of ceramic materials, such as tungsten carbide, can significantly increase the tool's resistance. The introduction of functionally graded materials is a significant contribution, opening up new possibilities for gradual changes in the mechanical properties of the tool and optimizing its performance in different sections according to specific requirements. In this work, you will find an overview of individual applications and their utilization in the industry. Microstructural analyses have been conducted, providing detailed insights into the structure of individual components alongside examinations of the mechanical properties and tool life. These analyses offer a deeper understanding of the efficiency and reliability of the created tools, which is a key element for successful development in the field of cutting and forming tools. The production of functional surfaces and edges using DED technology can result in financial savings, as the entire tool doesn't have to be manufactured from expensive special alloys. The tool can be made from common steel, onto which a functional surface from special materials can be applied. Additionally, it allows for tool repairs after wear and tear, eliminating the need for producing a new part and contributing to an overall cost while reducing the environmental footprint. Overall, the combination of DED technology, functionally graded materials, and verified technologies collectively set a new standard for innovative and efficient development of cutting and forming tools in the modern industrial environment.

Keywords: additive manufacturing, directed energy deposition, DED, laser, cutting tools, forming tools, steel, nickel alloy

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Authors: Yong-Jun Jeon, Hyung-Pil Park, Min-Jae Song, Baeg-Soon Cha

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Following the recent trend of having increased demand in producing lighter-weight car bodies for improvement of automobile safety and gas mileage, there is a forming method that makes use of hot-stamping technique, which satisfies all conditions mentioned above. Hot-stamping is a forming technique with advantages of excellent formability, good dimensional precision and others since it is a process in which steel plates are heated up to temperatures of at least approximately 900°C after which forming is conducted in die at room temperature followed by rapid cooling. In addition, it has characteristics of allowing for improvement in material strength through achievement of quenching effect by having simultaneous forming and rapid cooling of material of high temperatures. However, there is insufficient information on the changes in material strength according to changes in material temperature with regards to material heating method and forming process in hot-stamping. Accordingly, this study aims to design and press die for T-type product of the scale models of the center pillar and to understand the changes in material strength in relation to changes in forming methods of hot-stamping process. Thus in order to understand the changes in material strength due to quenching effect among the hot-stamping process, material strength and material forming precision were to be studied while varying the forming and forming method when forming. For test methods, material strength was observed by using boron steel that has boron additives, which was heated up to 950°C, after which it was transferred to a die and was cooled down to material temperature of 400°C followed by air cooling process. During the forming and cooling process here, experiment was conducted with forming parameters of 2 holding rates and 3 flange heating rates wherein changing appearance in material strength according to changes forming method were observed by verifying forming strength and forming precision for each of the conditions.

Keywords: hot-stamping, formability, quenching, forming, press die, forming methods

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Authors: Yong-Nam Kwon

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In the present study, we have designed the hydro-mechanical forming in which AZ31 sheet was drawn to a kind of preform step following gas blow forming for accurate geometry. In order to judge a formability enhancement of AZ31 sheet, model geometry came from a practical automotive part which had quite depth with complicated curvatures, which was proven that a single sheet forming could not gave a successful part. Experimentally, we succeeded to make the model part with accurate dimension. The optimum forming conditions for respective forming steps were considered most important technical features of this hydro-mechanical and would be discussed in details. Also, the effort to avoid detrimental abnormal grain growth was given and discussed for a practical application.

Keywords: hydro-mechanical forming, AZ31, abnormal grain growth, model geometry

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Authors: P. Sawitri, S. Cdr. Sittha, T. Kritsana

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Flow forming is widely used in many industries, especially in defence technology industries. Pressure vessels requirements are high precision, light weight, seamless and optimum strength. For large pressure vessels, flow forming by 3 rollers machine were used. In case of long range rocket motor case flow forming and welding of pressure vessels have been used for manufacturing. Due to complication of welding process, researchers had developed 4 meters length pressure vessels without weldment by 4 rollers flow forming machine. Design and preparation of preform work pieces are performed. The optimization of flow forming parameter such as feed rate, spindle speed and depth of cut will be discussed. The experimental result shown relation of flow forming parameters to quality of flow formed tube and prototype pressure vessels have been made.

Keywords: flow forming, pressure vessel, four rollers, feed rate, spindle speed, cold work

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Authors: Foad Saadi

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Aim of this work was to determine the approximate Epoxy forming composition range of Cr-Zn system for the composites produced by forming compositing. It was predicted by MI edema semi-empirical model that the composition had to be in the range of 30-60 wt. % tin, while Cr-32Zn had the most susceptibility to produce amorphous composite. In the next stage, some different compositions of Cr-Zn were foamingly composited, where one of them had the proper predicted composition. Products were characterized by SDM analysis. There was a good agreement between calculation and experiments, in which Cr-32Zn composite had the most amorphization degree.

Keywords: Cr-Zn system, forming compositing, amorphous composite, MI edema model

Procedia PDF Downloads 263

Authors: Hyeong-Gyu Park, Hak-Gon Noh, Beom-Soo Kang, Jeong Kim

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Electromagnetic forming (EMF) process is one of a high-speed forming process, which uses an electromagnetic body (Lorentz) force to deform work-piece. Advantages of EMF are summarized as improvement of formability, reduction in wrinkling, non-contact forming. In this study, the spiral coil is considered to evaluate formability in terms of pressure distribution of the forming process. It also is represented forming results of numerical analysis using ANSYS code. In the numerical simulation, RLC circuit coupled with spiral coil was made to consider the design parameters such as system input current and electromagnetic force. The simulation results show that even though input peak currents level are same level in each case, forming condition is certainly different because of frequency of input current and magnitude of current density and magnetic flux density. Finally, the simulation results appear that electromagnetic forming force apparently affected by input current frequency which determines magnitude of current density and magnetic flux density.

Keywords: electromagnetic forming, high-speed forming, RLC circuit, Lorentz force

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Authors: Fatima Ghassan Al-Abtah, Naser Al-Huniti, Elsadig Mahdi

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As the lightest constructional metal on earth, magnesium alloys offer excellent potential for weight reduction in the transportation industry, and it was observed that some magnesium alloys exhibit superior ductility and superplastic behavior at high temperatures. The main limitation of the superplastic forming (SPF) includes the low production rate since it needs a long forming time for each part. Through this study, an SPF process that starts with a mechanical pre-forming stage is developed to promote formability and reduce forming time. A two-dimensional finite element model is used to simulate the process. The forming process consists of two steps. At the pre-forming step (deep drawing), the sheet is drawn into the die to a preselected level, using a mechanical punch, and at the second step (SPF) a pressurized gas is applied at a controlled rate. It is shown that a significant reduction in forming time and improved final thickness uniformity can be achieved when the hybrid forming technique is used, where the process achieved a fully formed part at 400°C. Investigation for the impact of different forming process parameters achieved by comparing forming time and the distribution of final thickness that were obtained from the simulation analysis. Maximum thinning decreased from over 67% to less than 55% and forming time significantly decreased by more than 6 minutes, and the required gas pressure profile was predicted for optimum forming process parameters based on the 0.001/sec target constant strain rate within the sheet.

Keywords: magnesium, plasticity, superplastic forming, finite element analysis

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Authors: Kittiphat Rattanachan

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The sheet metal forming process, the 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 alloy, which have the different cell unit, mechanical property and chemical composition. They were forming into cone shape specimens 100 mm diameter with different wall’s incline angle: 90o, 75o, and 60o. The investigation, the specimens were forming until the surface fracture was occurred. The experimental result showed that both materials with the smaller wall’s incline angle, the higher formability. The formability limited of the ferrous base alloy was approx. 60o wall’s incline angle. By nature, SS 400 was higher formability than SUS 304. This result could be used as the initial utilized data in designing the single point incremental forming parts.

Keywords: NC incremental forming, single point incremental forming, wall incline angle, formability

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Authors: Karla D. Vazquez-Valdez, Bradley P. Wynne

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In the last decades manufacturing needs have been changing, leading to the study of manufacturing methods that were underdeveloped, such as incremental forming processes like shear forming. These processes use rotating tools in constant local contact with the workpiece, which is often also rotating, to generate shape. This means much lower loads to forge large parts and no need for expensive special tooling. Potential has already been established by demonstrating manufacture of high-value products, e.g., turbine and satellite parts, with high dimensional accuracy from difficult to manufacture materials. Thus, huge opportunities exist for these processes to replace the current method of manufacture for a range of high value components, e.g., eliminating lengthy machining, reducing material waste and process times; or the manufacture of a complicated shape without the development of expensive tooling. However, little is known about the exact deformation conditions during processing and why certain materials are better than others for shear forming, leading to a lot of trial and error before production. Three alloys were used for this study: Ti-54M, Jethete M154, and IN718. General Microscopy and Electron Backscatter Diffraction (EBSD) were used to measure strains and orientation maps during shear forming. A Design of Experiments (DOE) analysis was also made in order to understand the impact of process parameters in the properties of the final workpieces. Such information was the key to develop a reliable Finite Element Method (FEM) model that closely resembles the deformation paths of this process. Finally, the potential of these three materials to be shear spun was studied using the FEM model and their Forming Limit Diagram (FLD) which led to the development of a rough methodology for testing the shear spinnability of various metals.

Keywords: shear forming, damage, principal strains, forming limit diagram

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Authors: Safa Boudhaouia, Mohamed Amen Gahbiche, Eliane Giraud, Wacef Ben Salem, Philippe Dal Santo

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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.

Keywords: incremental forming, numerical simulation, MPIF, multipoint forming

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Authors: Masoud Ghermezi

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Studying the sheet metals is one of the most important research areas in the field of metal forming due to their extensive applications in the aerospace industries. A useful method for determining the forming limit of these materials and consequently preventing the rupture of sheet metals during the forming process is the use of the forming limit curve (FLC). In addition to specifying the forming limit, this curve also delineates a boundary for the allowed values of strain in sheet metal forming; these characteristics of the FLC along with its accuracy of computation and wide range of applications have made this curve the basis of research in the present paper. This study presents a new model that not only agrees with the results obtained from the above mentioned theory, but also eliminates its shortcomings. In this theory, like in the M-K theory, a thin sheet with an inhomogeneity as a gradient thickness reduction with a sinusoidal function has been chosen and subjected to two-dimensional stress. Through analytical evaluation, ultimately, a governing differential equation has been obtained. The numerical solution of this equation for the range of positive strains (stretched region) yields the results that agree with the results obtained from M-K theory. Also the solution of this equation for the range of negative strains (tension region) completes the FLC curve. The findings obtained by applying this equation on two alloys with the hardening exponents of 0.4 and 0.24 indicate the validity of the presented equation.

Keywords: sheet metal, metal forming, forming limit curve (FLC), M-K theory

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Authors: M. Hassani, Y. Hassani, N. Ajudanioskooei, N. N. Benvid

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Laser Forming process as a non-contact thermal forming process is widely used to forming and bending of metallic and non-metallic sheets. In this process, according to laser irradiation along a specific path, sheet is bent. One of the most important output parameters in laser forming is bending angle that depends on process parameters such as physical and mechanical properties of materials, laser power, laser travel speed and the number of scan passes. In this paper, Artificial Neural Network and Fuzzy Logic System were used to predict of bending angle in laser forming process. Inputs to these models were laser travel speed and laser power. The comparison between artificial neural network and fuzzy logic models with experimental results has been shown both of these models have high ability to prediction of bending angles with minimum errors.

Keywords: artificial neural network, bending angle, fuzzy logic, laser forming

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Authors: Jinn-Jong Sheu, Cang-Fu Liang, Cheng-Hsien Yu

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This paper proposed the cold roll forming process and the die design methods for a 400mm by 400 mm square tube with 16 mm in thickness. The tubular blank made by cold roll forming is 508mm in diameter. The square tube roll forming process was designed considering the layout of rolls and the compression ratio distribution for each stand. The final tube corner radius and the edge straightness in the front end of the tube are to be controlled according to the tube specification. A five-stand forming design using four rolls at each stand was proposed to establish the base reference of square tube roll forming quality. Different numbers of pass and roll designs were proposed and compared to the base design in order to find the feasibility of increase pass number to improve the square tube quality. The proposed roll forming processes were simulated using FEM analysis. The thickness variations of the corner and the edge areas were examined. The maximum loads and the torques of each stand were calculated to study the power consumption of the roll forming machine. The simulation results showed the square tube thickness variations and concavity of the edge are acceptable with the JIS tube specifications for the base design. But the maximum loads and torques are very high. By changing the layout and the number of the rolls were able to obtain better tube geometry and decrease the maximum load and torque of each stand. This paper had shown the feasibility of designing the roll forming process and the layout of dies using FEM simulation. The obtained information is helpful to the roll forming machine design for a large size square tube making.

Keywords: cold roll forming, FEM analysis, roll forming die design, tube roll forming

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Authors: Amar Al-Obaidi, Verena Kräusel, Dirk Landgrebe

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Induction assisted single point incremental forming (IASPIF) is a flexible method and can be simply utilized to form a high strength alloys. Due to the interaction between the mechanical and thermal properties during IASPIF an evaluation for the process is necessary to be performed analytically. Therefore, a numerical simulation was carried out in this paper. The numerical analysis was operated at both room and elevated temperatures then compared with experimental results. Fully coupled dynamic temperature displacement explicit analysis was used to simulated the hot single point incremental forming. The numerical analysis was indicating that during hot single point incremental forming were a combination between complicated compression, tension and shear stresses. As a result, the equivalent plastic strain was increased excessively by rising both the formed part depth and the heating temperature during forming. Whereas, the forming forces were decreased from 5 kN at room temperature to 0.95 kN at elevated temperature. The simulation shows that the maximum true strain was occurred in the stretching zone which was the same as in experiment.

Keywords: induction heating, single point incremental forming, FE modeling, advanced high strength steel

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Authors: Shuo Tian, Xuepiao Bai, Jianqin Shang, Pengtao Gai, Yuansong Zeng

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Shot peen forming is an essential forming process for aircraft metal wing panel. With the development of computer simulation technology, scholars have proposed a numerical simulation method of shot peen forming based on stress field. Three shot peen forming indexes of crater diameter, shot speed and surface coverage are required as simulation parameters in the stress field method. It is necessary to establish the relationship between simulation and experimental process parameters in order to simulate the deformation under different shot peen forming parameters. The shot peen forming tests of the 2024-T351 aluminum alloy workpieces were carried out using uniform test design method, and three factors of air pressure, feed rate and shot flow were selected. The second-order response surface model between simulation parameters and uniform test factors was established by stepwise regression method using MATLAB software according to the results. The response surface model was combined with the stress field method to simulate the shot peen forming deformation of the workpiece. Compared with the experimental results, the simulated values were smaller than the corresponding test values, the maximum and average errors were 14.8% and 9%, respectively.

Keywords: shot peen forming, process parameter, response surface model, numerical simulation

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Authors: Ali Moarrefzadeh

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In metalworking, rolling is a metal forming process in which metal stock is passed through a pair of rolls. Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization temperature, then the process is termed as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is termed as cold rolling. In terms of usage, hot rolling processes more tonnage than any other manufacturing process, and cold rolling processes the most tonnage out of all cold working processes. This article describes the use of advanced tubing inspection NDT methods for boiler and heat exchanger equipment in the petrochemical industry to supplement major turnaround inspections. The methods presented include remote field eddy current, magnetic flux leakage, internal rotary inspection system and eddy current.

Keywords: hot forming, cold forming, metal, rolling, simulation

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Authors: Kyo Jin An, Bukyo Seo, Young-Chul Park

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The current trend in car market is increase of parts of automobile and weight in vehicle. It comes from improvement of vehicle performance. Outer tie rod is a part of component of steering system and it is lighter than the others. But, weight lightening is still required for improvement of car mileage. So, we have presented a model of aluminized outer tie rod, but the process of fabrication has to be checked to manufacture the product. Therefore, we have anticipated forming load, die stress and abrasion to use the program of forging interpretation in the part of hot forging process of outer tie rod in this study. Also, we have implemented the experiments design to use the table of orthogonal arrays to reduce the forming load.

Keywords: forming load, hot forging, orthogonal array, outer tie rod (OTR), multi–step forging

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Authors: M. A. Aleem, M. S. Awan

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Flat spiral coil for electromagnetic forming system has been modelled in FEMM 4.2 software. Copper strip was chosen as the material for designing the actuator coil. Relationship between height to width ratio (S-factor) of the copper strip and coil’s performance has been studied. Magnetic field intensities, eddy currents, and Lorentz force were calculated for the coils that were designed using six different 'S-factor' values (0.65, 0.75, 1.05, 1.25, 1.54 and 1.75), keeping the cross-sectional area of strip the same. Results obtained through simulation suggest that actuator coil with S-factor ~ 1 shows optimum forming performance as it exerts maximum Lorentz force (84 kN) on work piece. The same coils were fabricated and used for electromagnetic sheet forming experiments. Aluminum 6061 sheets of thickness 1.5 mm have been formed using different voltage levels of capacitor bank. Smooth forming profiles were obtained with dome heights 28, 35 and 40 mm in work piece at 800, 1150 and 1250 V respectively.

Keywords: FEM modelling, electromagnetic forming, spiral coil, Lorentz force

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Authors: A. Anbu Raj, V. Mugendiren

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Sheet metal forming is a vital manufacturing process used in automobile, aerospace, agricultural industries, etc. Incremental forming is a promising process providing a short and inexpensive way of forming complex three-dimensional parts without using die. The aim of this research is to study the forming behaviour of AA 5052, Aluminium Alloy, using incremental forming and also to study the FLD of cone shape AA 5052 Aluminium Alloy at room temperature and various annealing temperature. Initially the surface roughness and wall thickness through incremental forming on AA 5052 Aluminium Alloy sheet at room temperature is optimized by controlling the effects of forming parameters. The central composite design (CCD) was utilized to plan the experiment. The step depth, feed rate, and spindle speed were considered as input parameters in this study. The surface roughness and wall thickness were used as output response. The process performances such as average thickness and surface roughness were evaluated. The optimized results are taken for minimum surface roughness and maximum wall thickness. The optimal results are determined based on response surface methodology and the analysis of variance. Formability Limit Diagram is constructed on AA 5052 Aluminium Alloy at room temperature and various annealing temperature by using optimized process parameters from the response surface methodology. The cone has higher formability than the square pyramid and higher wall thickness distribution. Finally the FLD on cone shape and square pyramid shape at room temperature and the various annealing temperature is compared experimentally and simulated with Abaqus software.

Keywords: incremental forming, response surface methodology, optimization, wall thickness, surface roughness

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Authors: H. G. Noh, H. G. Park, B. S. Kang, J. Kim

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Electromagnetic forming process (EMF) is one of high-velocity forming processes using Lorentz force. Advantages of EMF are summarized as improvement of formability, reduction in wrinkling, non-contact forming. In this study, numerical simulations were conducted to determine the practical parameters for EMF process. A 2-D axis-symmetric electromagnetic model was considered based on the spiral type forming coil. In the numerical simulation, RLC circuit coupled with spiral coil was made to consider the design parameters such as system input current and electromagnetic force. In order to deform the sheet in the patter shape die, two types of spiral shape coil were considered to deform the pattern shape sheet. One is a spiral coil that has 6turns with dead zone at centre point. Another is a normal spiral coil without dead zone that has 8 turns. In the electric analysis, input current and magnetic force were compared and then plastic deformation was treated in the mechanical analysis for two coil cases. Deformation behaviour of dead zone coil case has good agreement with pattern shape die. As a result, deformation behaviour could be controlled by giving dead zone at centre of the coil in spiral shape coil case.

Keywords: electromagnetic forming, spiral coil, Lorentz force, manufacturing

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Authors: Anna Dziubinska

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The applications of magnesium alloys in transport include all kinds of vehicle wheels for cars, motorcycles, bicycles, trolleys, etc. Modern technologies of manufacturing products from these materials have been noticeably improved recently, creating new possibilities for their application. Continuously developed technologies for forming Mg alloys must not be overlooked, which make it possible to manufacture products with better properties compared to those obtained by casting only. The article reviews the specialized literature on magnesium wheel forming and presents a concept of technology for forging magnesium wheels for light vehicles from cast preforms. The research leading to these results has received funding from the Norway Grants 2014-2021 via the National Centre for Research and Development.

Keywords: forming, forging, magnesium alloy, wheels, vehicles

Procedia PDF Downloads 100

Authors: Masato Nishi, Tetsushi Kaburagi, Masashi Kurose, Tei Hirashima, Tetsusei Kurasiki

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The process of thermoforming a carbon fiber reinforced thermoplastic (CFRTP) has increased its presence in the automotive industry for its wide applicability to the mass production car. A non-isothermal forming for CFRTP can shorten its cycle time to less than 1 minute. In this paper, the textile reinforcement FE model which the authors proposed in a previous work is extended to the CFRTP model for non-isothermal forming simulation. The effect of thermoplastic is given by adding shell elements which consider thermal effect to the textile reinforcement model. By applying Reuss model to the stress calculation of thermoplastic, the proposed model can accurately predict in-plane shear behavior, which is the key deformation mode during forming, in the range of the process temperature. Using the proposed model, thermoforming simulation was conducted and the results are in good agreement with the experimental results.

Keywords: carbon fiber reinforced thermoplastic, finite element analysis, pre-impregnated textile composite, non-isothermal forming

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Authors: Yiğit Gürler, İbrahim Şimşek, Müge Savaştaer, Ayberk Karakuş, Alper Taşdemirci

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316L steel is frequently used in the industry due to its easy formability and accessibility in sheet metal forming processes. Numerical and experimental studies are frequently encountered in the literature to examine the mechanical behavior of 316L stainless steel during the forming process. 316L stainless steel is the most common material used in the production of plate heat exchangers and plate heat exchangers are produced by plastic deformation of the stainless steel. The motivation in this study is to determine the appropriate material model during the simulation of the sheet metal forming process. For this reason, two different material models were examined and Ls-Dyna material cards were created using material test data. These are MAT133_BARLAT_YLD2000 and MAT093_SIMPLIFIED_JOHNSON_COOK. In order to compare results of the tensile test & hydraulic bulge test performed both numerically and experimentally. The obtained results were evaluated comparatively and the most suitable material model was selected for the forming simulation. In future studies, this material model will be used in the numerical modeling of the sheet metal forming process.

Keywords: 316L, mechanical characterization, metal forming, Ls-Dyna

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Authors: Yujeong Shin, Seong Jin Cho, Jin Ho Kim

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In the textile-weaving machine, the reed is the core component to separate thousands of strands of yarn and to produce the fabric in a continuous high-speed movement. In addition, the reed affects the quality of the fiber. Therefore, the wire forming analysis of the main raw materials of the reed needs to be considered. Roll-forming is a key technology among the manufacturing process of reed wire using textile machine. A simulation of roll-forming line in accordance with the reduction rate is performed using LS-DYNA. The upper roller, fixed roller and reed wire are modeled by finite element. The roller is set to be rigid body and the wire of SUS430 is set to be flexible body. We predict the variation of the cross-sectional shape of the wire depending on the reduction ratio.

Keywords: textile machine, reed, rolling, reduction ratio, wire

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Authors: Zixuan Liu, Xin Zhang, Kexin He

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In the context of widespread prevalence of multiple diseases, medication safety has become a highly concerned issue affecting patient safety. Medication reconciliation plays a vital role in preventing potential medication risks. However, in medical practice, medication reconciliation faces various challenges, and there is a wide variety of medication reconciliation tools, making the selection of appropriate tools somewhat difficult. The article introduces and analyzes the currently available medication reconciliation tools, providing a reference for healthcare professionals to choose and apply the appropriate medication reconciliation tools.

Keywords: patient safety, medication reconciliation, tools, review

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Authors: Eshwara Prasad Koorapati, R. Raman Goud, Swadesh Kumar Singh

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In the present work forming limit diagrams and strain distribution profile diagrams for extra deep drawing steel at room and elevated temperatures have been determined experimentally by conducting stretch forming experiments by using designed and fabricated warm stretch forming tooling setup. With the help of forming Limit Diagrams (FLDs) and strain distribution profile diagrams the formability of Extra Deep Drawing steel has been analyzed and co-related with mechanical properties like strain hardening coefficient (n) and normal anisotropy (r−).Mechanical properties of EDD steel from room temperature to 4500 C were determined and discussed the impact of temperature on the properties like work hardening exponent (n) anisotropy (r-) and strength coefficient of the material. Also, the fractured surfaces after stretching have undergone the some metallurgical investigations and attempt has been made to co-relate with the formability of EDD steel sheets. They are co-related and good agreement with FLDs at various temperatures.

Keywords: FLD, micro hardness, strain distribution profile, stretch forming

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Authors: Saif N. Al-Bahry, Yahya M. Al-Wahaibi, Abdulkadir E. Elshafie, Ali S. Al-Bemani, Sanket J. Joshi

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Environmental pollution is a global problem and best possible solution is identifying and utilizing native microorganisms. One possible application of microbial product -biosurfactant is in bioremediation of hydrocarbon contaminated sites. We have screened forty two different petroleum contaminated sites from Oman, for biosurfactant producing spore-forming bacterial isolates. Initial screening showed that out of 42 soil samples, three showed reduction in surface tension (ST) and interfacial tension (IFT) within 24h of incubation at 40°C. Out of those 3 soil samples, one was further selected for isolation of bacteria and 14 different bacteria were isolated in pure form. Of those 14 spore-forming, rod shaped bacteria, two showed highest reduction in ST and IFT in the range of 70mN/m to < 35mN/m and 26.69mN/m to < 9mN/m, respectively within 24h. These bacterial biosurfactants may be utilized for bioremediation of oil-spills.

Keywords: bioremediation, hydrocarbon pollution, spore-forming bacteria, bio-surfactant

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Authors: Jemal Ebrahim Dessie, Lukács Zsolt

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High-strength aluminum alloys have drawn a lot of attention because of the expanding demand for lightweight vehicle design in the automotive sector. Due to poor formability at room temperature, warm and hot forming have been advised. However, warm and hot forming methods need more steps in the production process and an advanced tooling system. In contrast, since ordinary tools can be used, forming sheets at room temperature in the W temper condition is advantageous. However, springback of supersaturated sheets and their thinning are critical challenges and must be resolved during the use of this technique. In this study, AA6082-T6 aluminum alloy was solution heat treated at different oven temperatures and times using a specially designed and developed furnace in order to optimize the W-temper heat treatment temperature. A U-shaped bending test was carried out at different time periods between W-temper heat treatment and forming operation. Finite element analysis (FEA) of U-bending was conducted using AutoForm aiming to validate the experimental result. The uniaxial tensile and unload test was performed in order to determine the kinematic hardening behavior of the material and has been optimized in the Finite element code using systematic process improvement (SPI). In the simulation, the effect of friction coefficient & blank holder force was considered. Springback parameters were evaluated by the geometry adopted from the NUMISHEET ’93 benchmark problem. It is noted that the change of shape was higher at the more extended time periods between W-temper heat treatment and forming operation. Die radius was the most influential parameter at the flange springback. However, the change of shape shows an overall increasing tendency on the sidewall as the increase of radius of the punch than the radius of the die. The springback angles on the flange and sidewall seem to be highly influenced by the coefficient of friction than blank holding force, and the effect becomes increases as increasing the blank holding force.

Keywords: aluminum alloy, FEA, springback, SPI, U-bending, W-temper

Procedia PDF Downloads 70

Authors: Lei Zhu, Nan Li

Abstract:

Cold stamping has been widely applied in the automotive industry for the mass production of a great range of automotive panels. Predicting the springback to ensure the dimensional accuracy of the cold-stamped components is a critical step. The main approaches for the prediction and compensation of springback in cold stamping include running Finite Element (FE) simulations and conducting experiments, which require forming process expertise and can be time-consuming and expensive for the design of cold stamping tools. Machine learning technologies have been proven and successfully applied in learning complex system behaviours using presentative samples. These technologies exhibit the promising potential to be used as supporting design tools for metal forming technologies. This study, for the first time, presents a novel application of a Convolutional Neural Network (CNN) based surrogate model to predict the springback fields for variable U-shape cold bending geometries. A dataset is created based on the U-shape cold bending geometries and the corresponding FE simulations results. The dataset is then applied to train the CNN surrogate model. The result shows that the surrogate model can achieve near indistinguishable full-field predictions in real-time when compared with the FE simulation results. The application of CNN in efficient springback prediction can be adopted in industrial settings to aid both conceptual and final component designs for designers without having manufacturing knowledge.

Keywords: springback, cold stamping, convolutional neural networks, machine learning

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