An Analytical Prediction of Flange Wrinkling in Sheet Metal Forming

Wrinkling is one of the major defects in sheet metal forming. The ability to accurately predict the occurrence of wrinkling is critical to the design of tooling and processing parameters. An analytical approach for predicting the onset of flange wrinkling is presented. This method is based on the wrinkling criterion proposed by Cao and Boyce for predicting the buckling behavior of sheet metal under normal constraint. Using a combination of energy conservation and plastic bending theory, the analysis provides the critical buckling stress and wavelength as functions of normal pressure. The results are in excellent agreement with those obtained from Cao and Boyce's numerical approach, and also match well with the experimental results of a square cup forming. In addition, the effects of material properties on the wrinkling behavior are also discussed. The analytical method significantly reduces computational time and is suitable for direct engineering application.     

锥状凸模与柱形凸模圆孔翻边的比较分析

通过对锥状凸模与柱状凸模圆孔翻边应力应变分布的对比分析,阐明了采用锥状凸模进行圆孔翻边,可降低制件开裂处的周向应力,提高材料的极限变形程度和减少壁厚变簿。     

Prediction of flange wrinkling in deep drawing process using bifurcation criterion

Surface distortions in the form of wrinkles are often observed in sheet metals during stamping and other forming operations. Because of the trend in recent years towards thinner, higher-strength sheet metals, wrinkling is increasingly becoming a more common and troublesome mode of failure in sheet metal forming. The prediction and prevention of wrinkling during a sheet forming process are important issues for the design of part geometry and processing parameters. This paper treats the phenomenon of flange wrinkling as a bifurcated solution of the equations governing the deep drawing problem when the flat position of the flange becomes unstable. Hill’s bifurcation criterion is used to predict the onset of flange wrinkling in circular and square cup drawing. In particular, the maximum cup height that can be drawn without the onset of flange wrinkling is predicted for the given set of process parameters. A parametric study of the maximum cup height is also carried out with respect to various geometric, material and process parameters. Finite element formulation, based on the updated Lagrangian approach, is employed for the analysis. The incremental logarithmic strain measure, which allows the use of a large incremental deformation, is used. The stresses are updated in a material frame. The material is assumed to be elastic–plastic, strain hardening, yielding according to an anisotropic yield criterion of Barlat et al. (2005) [23] (named as Yld2004-18p). Isotropic power law hardening is assumed. Inertia forces are neglected due to small accelerations. Modified Newton–Raphson iterative technique is used to solve the nonlinear incremental equations.     

Hemming process with counteraction force to prevent creepage

Creepage, a typical phenomenon in the hemming process, can be defined as undesired roll-in of the panel at the bending line. Creepage also reduces the final panel width and makes the hemming radius larger. In this study, experimental observations are reported, and a finite element model, based on the LS-DYNA^® two dimensional plane strain solid formulation, is utilized to study the mechanics of how the hem flange bends and folds during the hemming process. A novel hemming process incorporating a counteraction force is proposed in order to prevent the creepage phenomenon during the hemming process. An experimental hemming tool was designed according to this concept, and optimization of the tooling geometry was carried out utilizing the finite element model. An experimental study was conducted to confirm that the new hemming process can prevent creep be employed to help retain a sharp radius during flanging operation.     

Modeling and validation of deformation process for incremental sheet forming

Incremental Sheet Forming (ISF) is an emerging sheet metal prototyping technology where a part is formed as one or more stylus tools are moving in a pre-determined path and deforming the sheet metal locally while the sheet blank is clamped along its periphery. A deformation analysis of incremental forming process is presented in this paper. The analysis includes the development of an analytical model for strain distributions based on part geometry and tool paths, numerical simulations of the forming process with LS-DYNA, and experimental validation of strain predictions using Digital Image Correlation (DIC) techniques. Three kinds of parts include hyperbolic cone, skew cone and elliptical cone are constructed and used as examples for the study. Analytical, numerical and experimental results are compared, and excellent correlations are found. It is demonstrated that the analytical model developed in this paper is reliable and efficient in the prediction of strain distributions for incremental forming process.     

The strain gradient approach to predict necking in tube hydroforming

A stress-based forming limit diagram for necking prediction which is based on the strain gradient theory of plasticity in conjunction with the M–K model has been represented and used in tube hydroforming. In this study, the finite element model for bulge forming of straight tube has been constructed and verified with published experimental data. The adaptive simulation technique is based on the ability to detect the onset and growth of defects (e.g., wrinkling, and bursting) and to promptly readjust the loading paths. Thus, a suitable load path has been obtained by applying Adaptive Simulation Method in ANSYS Parametric Design Language (APDL).     

Part 2: Analytical modeling of regular planar polygon tube hydroforming as a special case of symmetric multi-nose tube hydroforming

Part 2 of this series of papers presents an analytical model for regular planar polygon tube hydroforming (THF) as a special case of the analytical model for symmetric multi-nose tube hydroforming. The governing equations derived for multi-nose THF in Part 1 were evaluated by taking the limit of die geometric variables, resulting in a new set of governing equations for regular polygon THF. The model was validated using finite element analysis and a THF experiment, where good agreement was obtained. The model is able to predict field variables such as stresses and strain distribution, thinning rate distribution, and deformed shape at a particular pressure.     

板料成形模拟中压边力处理的研究

针对弹性压边建立了一个力学模型 ,用于板料成形的动力显式有限元模拟。以NU MISHEET’93方盒拉深标准考题为例 ,模拟了方盒在不同压边力情况下的起皱情况。数值计算结果表明该模型能有效地模拟弹性压边力 ,并预测工件法兰部位的起皱状况。     

筒形件反拉深数值模拟的关键技术

结合对Numisheet’99标准考题的模拟研究，论述了反拉深成形过程有限元模拟的关键技术问题，涉及反拉深成形过程的强化模型、接触、起皱、破裂及回弹计算等，并介绍主要模拟结果。     

汽车左/右后轮罩冲压工艺及翻边、斜楔翻边模具设计

根据制件的特点 ,分析了其冲压成形的工艺难点 ,制定了合理的工艺 ,简化了模具设计和制造 ,并画出了制件的综合工序图 ,分析了各工序内容和工艺特点 ,说明了各工序模具设计的关键问题。同时以第 5道工序为例 ,重点分析了斜楔翻边、翻边模的结构、工作原理及设计要点     

薄壁三通管翻边成形工艺参数的确定

介绍了薄壁三通管翻边成形时预制孔形状及极限翻边高度的确定方法。     

高压开关静触头座成形工艺

介绍了采用冲压 旋压复合工艺成形静触头座的过程。其中包括 :变薄旋压成形薄壁筒体 ,扩口翻边成形法兰 ,普旋方式成形异形管口等。对主要工艺参数如主轴转速、进给率、旋轮形状、道次变形率、模板形式等作了简要介绍。该成形工艺对同类异形回转体有一定参考意义。     

Prediction of polycrystalline materials texture evolution in machining via Viscoplastic Self-Consistent modeling

The crystallographic orientation or anisotropy is one of the main microstructural attributes strongly affecting the mechanical properties of materials. It is also an influential parameter to be considered during the manufacturing process especially for ultra-precision machining since it affects part quality, tool performance, and process productivity through material properties. In this study, a prediction toolset constituted of a Viscoplastic Self-Consistent model and machining process mechanics model is used to predict the texture evolution on the machined surface. The VPSC (Viscoplastic Self-Consistent) methodology which uses the mechanisms of slip and twinning that are active in single crystals of arbitrary symmetry was used. For this, an analytical model for the process mechanics is derived to understand the forces and stresses generated by the cutting tool at each workpiece point, then the strain and strain rate to capture the rate at which the material is deforming and finally the crystallographic orientations under various machining conditions. Experiments were performed on the orthogonal cutting of aluminum alloy AA-7075-T651 and the texture results were compared to model predictions.     

拉伸类冲压成形性能非线性关系评定

同时用板材的加工硬化指数n值与各向异性系数r值对极限翻边系数K_(f,c)和极限胀形系数K_(b,c)的定量预报作用和公式;K_(f,c)=1/((1+r)n+1),K_(b,c)=(1+r)n+1.从而获得了板材拉伸类冲压成形性能用r×n去作非线性关系评定的实验研究结果.     

抛物形件用软凸模拉深成形

分析了抛物形件用软凸模拉深过程,用聚氨酯橡胶凸模能简化抛物形件的制造工艺,有效地防止拉裂、起皱和回弹,给出了软凸模拉深系数和合适的软模硬度。     

快速城市化进程中海岛景观格局演变及驱动机制以大长山岛为例

城市化进程改变了区域的景观结构,引起了景观格局的变化。以大长山岛两期景观分布图为数据源,运用景观生态学的理论与方法,利用景观格局指数定量分析了1995~2006年景观格局的动态变化特征,在此基础上借助CA-Markov模型对大长山岛2017年景观格局进行了模拟与预测,并探讨了景观格局演变驱动机制。结果表明:大长山岛在快速城市化的进程中,景观格局演变的总规律为自然景观向人文景观转变。1995~2006年间,主要表现为农用地、草地、商业及工矿用地面积减少,园林地、水体及水利设施、居民点及公共服务和其它用地增加;而2006~2017年间,表现为农用地、草地、园林地面积减少,居民点及公共服务、水体及水利设施、商业及工矿用地和其它用地增加,但在此期间各景观类型的面积减少和增加的速度有所放缓。     

Analytical modelling of residual stresses in orthogonal machining of AISI4340 steel

Residual stress profile in a component is often considered as the critical characteristic as it directly affects the fatigue life of a machined component. This work presents an analytical model for the prediction of residual stresses in orthogonal machining of AISI4340 steel. The novelty of the model lies in the physics-based approach focusing on the nature of contact stresses in various machining zones and the effect of machining temperature. The model incorporates: (i) stresses in three contact regions viz. shear, tool-nose-work piece and tool flank and machined surface, (ii) machining temperature, (iii) strain, strain rate and temperature dependent work material properties, (iv) plastic stresses evaluation by two algorithms, S-J and hybrid, (v) relaxation procedure and (iv) cutting conditions. The model benchmarking shows (86–88%) agreement between the experimental and predicted residual stresses in the X- and Y-directions. On the machined surface, the tensile residual stresses decrease with an increase the edge radius and increase with an increase the cutting speed. However, below the surface, the compressive residual stresses increase with an increase the depth of cut. Further, it is observed that the proposed model with hybrid algorithm gives better results at a lower feed rate, whereas with the S-J algorithm, at a higher feed rate.     

摩托车离合器压套的冲压工艺与模具设计

通过对压套零件的冲压工艺分析,省去外缘修边工序。外缘翻边时,利用板料的塑性平面各向异性在拉深件凸缘处产生的凸耳,翻边后形成图纸要求的凸、凹R50mm的外形尺寸,成功地用四套模具生产出摩托车离合器压套零件,降低了模具成本,提高了材料利用率。     

Effect of specimen planar area on electromagnetic flanging

The specimen parameter that is often mentioned with respect to the ability to achieve electromagnetic forming (EMF) is the specimen thickness. If the skin depth is small compared to this parameter, efficient forming will be achieved. However, another parameter that may affect the ability to achieve efficient forming is the specimen's planar area, i.e., the length and width of the specimen. This would particularly become an important factor if EMF is used to fabricate meso/microscale components. In this research, a flat spiral coil was used to flange 0.508 mm thickness, CuZn30 specimens of varying widths (i.e., 10, 14, 18, 22, 35, and 47 mm). These widths were varied in order to modify the projected area of the coil over the specimen. Results showed that a decrease in the specimen width was generally associated with a decrease in forming (i.e., lower flanging angle) due to edge effects in induced eddy currents. Since the magnetic field distribution from the flat spiral coil is asymmetric, material was overhung on both sides of the die. This yielded an extra half turn on the left side of the specimen, and increased forming. The die was also translated to assess differences in flanging generated. In order to achieve meso/microforming with EMF, attention to the interaction between coil design and specimen dimensions is required.     

YBT试验与板材抗皱性

方板对角拉伸试验(统称为YBT—Yoshida Buckling Test)是研究复杂钣金件成形中非均匀拉伸起皱的一种模拟试验。此文测量和分析了起皱过程,在试验的基础上探讨了板材性能、板厚和材料方向性、加载条件等因素对板材抗皱性的影响。