Search results for: Sheet metal forming.

Authors: M. Mahboubkhah, H. Fayazfar

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.

Keywords: Forming Limit Diagram, Major and Minor Strain, Measurement Uncertainty.

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Authors: Hongyu Wei, Wenliang Chen, Lin Gao

Abstract:

Incremental forming is a complex forming process with continuously local cumulative deformation taking place during its process, and springback that forming quality affected by would occur. The springback evaluation method based on forming error compensation also was proposed, which it can be defined as the difference between theory and the actual amount of compensation along the measured direction. According to forming error compensation evaluation method, experiments was designed and implemented. And from the results that obtained it can be show, the magnitude of springback average (δE) of formed parts was very small, and the forming precision could be significantly improved by adopting compensation method. Based on double tensile stress state in the main deformation area, a hypothesis that there is little springback be arisen by bending behavior on the formed parts that was proposed.

Keywords: Sheet metal, incremental forming, springback, forming error compensation, geometric accuracy

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Authors: Maziar Ramezani, Thomas Neitzert, Timotius Pasang

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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.

Keywords: Friction, L-bending, Springback, Stribeck curves.

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Authors: A. Pourkamali Anaraki, M. Shahabizadeh, B. Babaee

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.

Keywords: Deep drawing, Finite element method, Simulation.

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Authors: Bahaa Eltahawy, Mikko Ylihärsilä, Reino Virrankoski, Esko Petäjä

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.

Keywords: Feature recognition, automation, sheet metal manufacturing, CAM, CAD.

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Authors: A. Soualem

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.

Keywords: Deep drawing, Expansion, Restreint deep drawing, Springback.

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Authors: Amir Ansari, Ehsan Shahrjerdi, Ehsan Amini

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.

Keywords: Rubber pad forming, Tailor welded blank, Thickness ratio, Weld line displacement.

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Authors: S. Onoda, S. Yoshihara, B. J. MacDonald, Y. Okude

Abstract:

Aluminum alloy sheets have several advantages such as the lightweight, high-specific strength and recycling efficiency. Therefore, aluminum alloy sheets in sheet forming have been used in various areas as automotive components and so forth. During the process of sheet forming, wrinkling which is caused by compression stress might occur and the formability of sheets was affected by occurrence of wrinkling. A few studies of uniaxial compressive test by using square tubes, pipes and sheets were carried out to clarify the each wrinkling behavior. However, on uniaxial compressive test, deformation behavior of the sheets hasn-t be cleared. Then, it is necessary to clarify the relationship between the buckling behavior and the forming conditions. In this study, the effect of dimension of the sheet in the buckling behavior on compression test of aluminum alloy sheet was cleared by experiment and FEA. As the results, the buckling deformation was classified by three modes in terms of the distribution of equivalent plastic strain.

Keywords: Sheet forming, Compression test, Aluminum alloy sheet, Buckling behavior

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Authors: Awais Ahmad Khan, Emad Abouel Nasr, H. M. A. Hussein, Abdulrahman Al-Ahmari

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.

Keywords: Feature Extraction, Internal Features, Punch Shapes, Sheet metal, STEP.

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Authors: Morteza Khaleghi, Babak Seyed Aghazadeh, Hosein Bisadi

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.

Keywords: Sheet metal forming, Gas detonation, FEM, Oxyhydrogen

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Authors: M. Hosseinzadeh, S. A. Zamani, A. Taheri

Abstract:

During the last few years, several sheet hydroforming processes have been introduced. Despite the advantages of these methods, they have some limitations. Of the processes, the two main ones are the standard hydroforming and hydromechanical deep drawing. A new sheet hydroforming die set was proposed that has the advantages of both processes and eliminates their limitations. In this method, a polyurethane plate was used as a part of the die-set to control the blank holder force. This paper outlines the Taguchi optimization methodology, which is applied to optimize the effective parameters in forming cylindrical cups by the new die set of sheet hydroforming process. The process parameters evaluated in this research are polyurethane hardness, polyurethane thickness, forming pressure path and polyurethane hole diameter. The design of experiments based upon L9 orthogonal arrays by Taguchi was used and analysis of variance (ANOVA) was employed to analyze the effect of these parameters on the forming pressure. The analysis of the results showed that the optimal combination for low forming pressure is harder polyurethane, bigger diameter of polyurethane hole and thinner polyurethane. Finally, the confirmation test was derived based on the optimal combination of parameters and it was shown that the Taguchi method is suitable to examine the optimization process.

Keywords: Sheet Hydroforming, Optimization, Taguchi Method

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Authors: D. Singh, R. Yousefi, M. Boroushaki

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.

Keywords: Deep-drawing, Neural network, Genetic algorithm, Sheet metal forming.

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Authors: Maziar Ramezani, Zaidi Mohd Ripin

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

Keywords: Friction model, Stress distribution, V-bending.

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Authors: K. Rattanachan

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.

Keywords: NC incremental forming, Single point incremental forming, Wall incline angle, Formability.

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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: K. Kalaiselvan, A. Elango

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.

Keywords: Laser Beam Welding (LBW), dissimilar metals, Ti/Al, SS/Al and Cu/Al sheets.

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Authors: R. Alipour, F.Najarian

Abstract:

Because of high ductility, aluminum alloys, have been widely used as an important base of metal forming industries. But the main week point of these alloys is their low strength so in forming them with conventional methods like deep drawing, hydro forming, etc have been always faced with problems like fracture during of forming process. Because of this, recently using of explosive forming method for forming of these plates has been recommended. In this paper free explosive forming of A2024 aluminum alloy is numerically simulated and during it, explosion wave propagation process is studied. Consequences of this simulation can be effective in prediction of quality of production. These consequences are compared with an experimental test and show the superiority of this method to similar methods like hydro forming and deep drawing.

Keywords: Free explosive forming, CEL, Johnson cook.

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Authors: L.C. Kgomari, R.K.K.Mbaya

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This research was conducted to develop a correlation between microstructure of HSLA steel and the mechanical properties that occur as a result of both laser and mechanical forming processes of the metal. The technique of forming flat metals by applying laser beams is a relatively new concept in the manufacturing industry. However, the effects of laser energy on the stability of metal alloy phases have not yet been elucidated in terms of phase transformations and microhardness. In this work, CO2 laser source was used to irradiate the surface of a flat metal then the microstructure and microhardness of the metal were studied on the formed specimen. The extent to which the microstructure changed depended on the heat inputs of up to 1000 J/cm2 with cooling rates of about 4.8E+02 K/s. Experimental results revealed that the irradiated surface of a HSLA steel had transformed to austenitic structure during the heating process.

Keywords: Laser, Forming, Microstructure

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Authors: Hossein Mamusi, Abolfazl Masoumi, Ramezanali Mahdavinezhad

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.

Keywords: TWB, Forming Limit Diagram, Necking criteria, ABAQUS/Explicit

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Authors: Kateřina Jurdová

Abstract:

Hanging to the trapezoidal sheet by decking hanger is a very widespread solution used in civil engineering to lead the distribution of energy, sanitary, air distribution system etc. under the roof or floor structure. The trapezoidal decking hanger is usually a part of the whole installation system for specific distribution medium. The leading companies offer installation systems for each specific distribution e.g. pipe rings, sprinkler systems, installation channels etc. Every specific part is connected to the base connector which is decking hanger. The own connection has three main components: decking hanger, threaded bar with nuts and web of trapezoidal sheet. The aim of this contribution is determinate the failure mechanism of each component in connection. Load bearing capacity of most components in connection could be calculated by formulas in European codes. This contribution is focused on problematic of bearing resistance of threaded bar in web of trapezoidal sheet. This issue is studied by experimental research and numerical modelling. This contribution presented the initial results of experiment which is compared with numerical model of specimen.

Keywords: Decking hanger, concentrated load, connection, load bearing capacity, trapezoidal metal sheet.

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Authors: Sunthorn S., Kittiphat R.

Abstract:

The edge waviness in hot rolled steel is a common defect. Variables that affect such defect include raw material and machine. These variables are necessary to consider to understand such defect. This research studied the defect of edge waviness for SS 400 of metal sheet manufacture. Defect of metal sheets were divided into two groups. The specimens were investigated on chemical composition and mechanical properties to find the difference. The results of investigation showed that the difference was not significant. Therefore the roll mill machine should be used to adjust to support another location on a roller to avoide edge waviness.

Keywords: Edge waviness, Hot rolling steel, Metal sheet defect, SS 400, Roll leveler.

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Authors: Didik Nurhadiyanto , Moch Agus Choiron , Ken Kaminishi , Shigeyuki Haruyama

Abstract:

At the previous study of new metal gasket, contact width and contact stress were important design parameter for optimizing metal gasket performance. However, the range of contact stress had not been investigated thoroughly. In this study, we conducted a gasket design optimization based on an elastic and plastic contact stress analysis considering forming effect using FEM. The gasket model was simulated by using two simulation stages which is forming and tightening simulation. The optimum design based on an elastic and plastic contact stress was founded. Final evaluation was determined by helium leak quantity to check leakage performance of both type of gaskets. The helium leak test shows that a gasket based on the plastic contact stress design better than based on elastic stress design.

Keywords: Contact stress, metal gasket, plastic, elastic

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Authors: Shakil A. Kagzi, Sanjay Patil, Harit K. Raval

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.

Keywords: ANOVA, Deep drawing, Tailor Welded Blank, TWB, Weld line movement.

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Authors: Kateřina Jurdová

Abstract:

In most industrial compounds are used trapezoidal metal sheets like a roof decks. These trapezoidal metal sheets are exposed by concentrated loads, usually by service loads arise from installation of air distribution, sanitary distribution, sprinkler system or wiring installation. In objects of public facilities (like shopping centre, tennis hall, etc.) they can be used for hanging advertising posters etc, too. These systems work as “building kit”. These anchoring systems are represented by clamps in shape of “V”.

This paper is occupy with recapitulation of installation systems available in trade with focus on load-bearing capacity specified by producer and on possible methods, how exactly define load bearing capacity of trapezoidal sheet loaded by concentrated load. The load bearing capacity was verified at experimental samples to determine real behavior of trapezoidal metal sheets exposed to concentrated loads.

Keywords: Clamps, concentrated load, loading test, trapezoidal metal sheet.

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Authors: Morteza Khaleghi Meybodi, Hossein Bisadi

Abstract:

Explosive forming is one of the unconventional techniques in which, most commonly, the water is used as the pressure transmission medium. One of the newest methods in explosive forming is gas detonation forming which uses a normal shock wave derived of gas detonation, to form sheet metals. For this purpose a detonation is developed from the reaction of H2+O2 mixture in a long cylindrical detonation tube. The detonation wave goes through the detonation tube and acts as a blast load on the steel blank and forms it. Experimental results are compared with a finite element model; and the comparison of the experimental and numerical results obtained from strain, thickness variation and deformed geometry is carried out. Numerical and experimental results showed approximately 75 – 90 % similarity in formability of desired shape. Also optimum percent of gas mixture obtained when we mix 68% H2 with 32% O2.

Keywords: Explosive forming, High strain rate, Gas detonation, Finite element analysis.

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

Abstract:

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: Lucie Novakova, Petr Homola, Vaclav Kafka

Abstract:

Asymmetric incremental sheet forming (AISF) could significantly reduce costs incurred by the fabrication of complex industrial components with a minimal environmental impact. The AISF experiments were carried out on commercially pure titanium (Ti-Gr2), Timetal (15-3-3-3) alloy, and Ti-6Al-4V (Ti-Gr5) alloy. A special testing geometry was used to characterize the titanium alloys properties from the point of view of the forming zone and titanium structure effect. The structure and properties of the materials were assessed by means of metallographic analyses and microhardness measurements.The highest differences in the parameters assessed as a function of the sampling zone were observed in the case of alpha-phase Ti-Gr2at the expense of the most substantial sheet thinning occurrence. A springback causes a smaller stored deformation in Timetal (β alloy) resulting in less pronounced microstructure refinement and microhardness increase. Ti-6Al-4V alloy exhibited early failure due to its poor formability at ambient temperature.

 

Keywords: Incremental forming, metallography, hardness, titanium alloys.

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Authors: A. Soualem

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.

Keywords: Blank holder force, Deep-Drawing, Die radius, Forming, Springback.

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Authors: Vishal Naranje, Shailendra Kumar

Abstract:

Metal stamping die design is a complex, experiencebased and time-consuming task. Various artificial intelligence (AI) techniques are being used by worldwide researchers for stamping die design to reduce complexity, dependence on human expertise and time taken in design process as well as to improve design efficiency. In this paper a comprehensive review of applications of AI techniques in manufacturability evaluation of sheet metal parts, die design and process planning of metal stamping die is presented. Further the salient features of major research work published in the area of metal stamping are presented in tabular form and scope of future research work is identified.

Keywords: Artificial Intelligence, Die design, ManufacturabilityEvaluation, Metal Stamping Die.

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Authors: Muhamad Sani Buang, Shahrul Azam Abdullah, Juri Saedon

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.  

Keywords: Advance high strength steel, U-channel process, Springback, Design of Experiment, Optimization, Response Surface Methodology (RSM).

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