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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. 相似文献
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《Journal of Manufacturing Processes》2000,2(2):100-107
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. 相似文献
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《Journal of Manufacturing Processes》2000,2(4):225-240
A new approach to theoretical modeling and simulation of face milling forces is presented. The present approach is based on a predictive machining theory in which machining characteristic factors in continuous cutting with a single-point cutting tool can be predicted from the workpiece material properties, tool geometry, and cutting conditions. The action of a milling cutter is considered as the simultaneous work of a number of single-point cutting tools, and the milling forces are predicted from input data of workpiece material properties, cutter parameters and tooth geometry, cutting condition, cutter and workpiece vibration structure parameters, and types of milling. A predictive force model for face milling is developed using this approach. In the model, the workpiece material properties are considered as functions of strain, strain rate, and temperature. The ratio of cutter tooth engagement over milling is taken into account for the determination of temperature in the cutting region. Cutter runout is included in the modeling for the chip load. The relative displacement between the cutter and workpiece due to the cutter and workpiece vibration is also included in the modeling to consider the effect on the undeformed chip thickness. A milling force simulation system has been developed using the model, and face milling experimental tests have been conducted to verify the simulation system. It is shown that the simulation results agree well with experimental results. 相似文献
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《Journal of Manufacturing Processes》2014,16(3):363-372
The dimpling process is a novel cold-roll forming process that involves dimpling of a rolled flat strip prior to the roll forming operation. This is a process undertaken to enhance the material properties and subsequent products’ structural performance while maintaining a minimum strip thickness. In order to understand the complex and interrelated nonlinear changes in contact, geometry and material properties that occur in the process, it is necessary to accurately simulate the process and validate through physical tests. In this paper, 3D non-linear finite element analysis was employed to simulate the dimpling process and mechanical testing of the subsequent dimpled sheets, in which the dimple geometry and material properties data were directly transferred from the dimpling process. Physical measurements, tensile and bending tests on dimpled sheet steel were conducted to evaluate the simulation results. Simulation of the dimpling process identified the amount of non-uniform plastic strain introduced and the manner in which this was distributed through the sheet. The plastic strain resulted in strain hardening which could correlate to the increase in the strength of the dimpled steel when compared to plain steel originating from the same coil material. A parametric study revealed that the amount of plastic strain depends upon on the process parameters such as friction and overlapping gap between the two forming rolls. The results derived from simulations of the tensile and bending tests were in good agreement with the experimental ones. The validation indicates that the finite element analysis was able to successfully simulate the dimpling process and mechanical properties of the subsequent dimpled steel products. 相似文献
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The deformation inhomogeneity of flat wires produced with roll drawing process is analyzed. The effect of main process parameters, i.e., initial wire diameter, forming roll dimension and thickness reduction on deformation inhomogeneity is established by means of experimental tests and a developed FE model. Vickers microhardness–strain relationship is developed for the analyzed material (low carbon steel AISI-1010) by correlating the microhardness measurements and effective strain fields as predicted by an axisymmetric numerical model of a compression test. A non-linear finite element model of roll drawing process is developed for a thorough understanding of process parameters effect on deformation inhomogeneity. Thus, in order to encompass the wide range of process conditions, an inhomogeneity index, calculated as the coefficient of variation of effective strain, is used. The numerical results showed that the inhomogeneity factor of flat wires produced with roll drawing is highly dependent on area reduction. 相似文献
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Joseph F. Wilson Brad L. Kinsey Yannis P. Korkolis 《Journal of Manufacturing Processes》2013,15(4):580-585
Characterization of the evolving yield loci and forming limit diagrams for sheet materials under biaxial loading is necessary for the development of accurate sheet metal forming process simulations. Biaxial tension testing has been shown to have significant advantages over the current computational and experimental methods for such material characterization; however, the few commercially available loading frames are far too large and expensive to be practical for most metal forming research laboratories. In this paper, the design of a practical servohydraulic biaxial loading frame is presented. The design, control, and operation of the loading frame are discussed in detail, and experimental data is provided to validate the effectiveness of the control system with respect to specimen center shifting. 相似文献
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黄土高原水土流失区粮食现状与增产潜力研究 总被引:7,自引:0,他引:7
以黄土高原10个试区的攻关资料为基础,从区域旱作产量潜势、试区攻关水平和试区所在县的产量现状三个层次,详细剖析了黄土高原水土流失区粮食现状和增产潜力。结果指出,该区粮食增产潜力很大,目前整体产量水平仅达到试区攻关水平的74.7%,达到旱作粮食产量潜势水平的54.2%。在黄土台塬区和丘陵区中,丘陵区的粮食增产潜力较台塬区大,前者尚有117.6%增产能力,后者仅56.6%。但考虑到人口增长和坡耕地的退垦等因素,未来30年内黄土高原水土流失区的粮食供需仍处于负平衡。 相似文献
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Dongkai Xu Rajiv Malhotra N. Venkata Reddy Jun Chen Jian Cao 《Journal of Manufacturing Processes》2012,14(4):487-494
Single point incremental forming (SPIF) is a new sheet metal forming process characterized by higher formability, product independent tooling and greater process flexibility. The inability of conventional single pass SPIF to form vertical walls without failure is overcome by forming multiple intermediate shapes before forming the final component, i.e., multi-pass single point incremental forming (MSPIF). A major issue with MSPIF is significant geometric inaccuracy of the formed component, due to the generation of stepped features on the base. This work proposes analytical formulations that are shown to accurately and quantitatively predict the stepped feature formation in MSPIF. Additionally, a relationship is derived among the material constants used in these analytical equations, the yield stress and thickness of the blank material, such that the computational effort required for the calibration of these constants can be minimized. Finally, the physical effects of yield stress and sheet thickness on the rigid body translation are further discussed. 相似文献
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目的准确地对热塑性复合材料前缘结构进行抗鸟撞冲击设计。方法首先基于刚度退化、材料塑性及应变率影响的复合材料本构关系,通过霍普金森拉-压杆测试得到热塑性复合材料的动力学性能参数。基于不同的失效模式,采用PAM-CRASH显式有限元法,针对运输类飞机热塑性复合材料机翼前缘结构在高速冲击时的破坏形式进行对比分析研究。结果热塑性复合材料较其他复合材料在临界拉伸损伤极限值和纵横向及屈服应力的率相关性上具有更好的性能。冲击分析时,失效应变应考虑材料破坏瞬间的强化效应。剪切应变取值为0.1左右时,前缘结构计算仿真失效的结果与试验结果一致性较高,应变误差仅为6.2%,破坏尺寸误差为4.9%。结论在复合材料失效参数较复杂的情况下,抗冲击设计可将拉伸、压缩、剪切及层间失效等多目标优化设计简化为等效剪切应变失效的单目标优化,此方法可推广应用于其他类型复合材料的抗冲击设计。 相似文献
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《Journal of Manufacturing Processes》2003,5(2):127-142
Geometric parameters and material properties are the two major categories of factors affecting burr formation in the milling process. Geometric parameters such as tool geometry, workpiece geometry, or process condition influence workpiece edge quality at the tool-chip interface. This study identifies a unified criterion to analyze burr formation for different tool engagements. The criterion exploits the exit order of cutting edges of the tool along the workpiece edge, which essentially includes the 3-D nature of the process. The criterion correlates the cutting mechanism and burr formation using the exit order sequence (EOS) as an approximation of chip flow angle. The impact of different possible exit order sequences on burr formation is analyzed. Previously observed phenomena are explained based on the EOS. Also, experiments are done with three different materials (with different ductilities) to analyze the impact of material properties on burr formation for a given EOS. Although burr sizes are different quantitatively with different material, the ranking of burr size for different EOS remained the same. An algorithm for the prediction of burr formation in face milling based on EOS is developed and tested and validated on two different profiles of an automotive part. 相似文献
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Farhang Pourboghrat Senthilkumar Venkatesan John E. Carsley 《Journal of Manufacturing Processes》2013,15(4):600-615
The goal of the research was to determine the limits and conditions in which the sheet hydroforming process provides a significant advantage over stamping in deep drawing of AA5754 aluminum sheets. Specifically, the maximum draw depth achievable by stamping, warm stamping (WF), sheet hydroforming (SHF), and sheet thermo-hydroforming (THF) of AA5754 aluminum alloy were quantified through experimental and computational modeling. A limited number of forming experiments were conducted with AA5754 aluminum sheets using a cylindrical punch and counteracting fluid at different temperatures and pressures. Several parameters, such as force–displacement, hydroforming pressure and temperature, and the maximum draw depth prior to wrinkling or tearing were measured during the forming process to make comparisons with simulations. The computational study included the simulation of stamping, WF, SHF and THF of AA5754 aluminum sheet with the LS-Dyna code, and the Barlat 2000-2d yield function with temperature-dependent coefficients. To predict the onset of wrinkling and tearing, the numerically generated, temperature-dependent forming limit diagrams (FLDs) based on the Barlat 2000-2d yield function were used. It was found that compared with stamping, SHF and THF can achieve more than 100% deeper draw depths with AA5754 aluminum sheet. The stamping simulations were used also to calculate the optimum blank size and die corner radii for the limiting draw ratio (LDR). The LDR was found to be very sensitive to the punch and die corner radii used in the experiments, which represent the curvature of character lines in an actual part. The LDR for AA5754 aluminum sheet was found to be 1.33 and 2.21 for sharp and round die corner radii, respectively. Overall, it was concluded that SHF is most ideal for deep drawing of aluminum sheets with sharp radii features. With the additional drawability provided by SHF, the automotive industry would be able to make difficult-to-form aluminum parts that cannot be stamped without product concessions such as increasing the die radii. 相似文献
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《Journal of Manufacturing Processes》2014,16(2):284-295
Cylindrical as well as conical cross-section structural parts are widely used in industrial applications worldwide. Such parts are produced from metal plates using many manufacturing methods. 3-roller conical bending process is one such process. In this process first the metal plates in specified blank shapes are given static bending in the rollers. Then the rollers are driven using motors for bending of the blanks under dynamic condition. During bending reaction forces will be there on the rollers. Forces acting on the rollers during the process are transmitted to the machine frame at the roller supports. In the paper an analytical model is developed for the prediction of force during the stage of dynamic bending. The model consists of various parameters like material parameters and geometrical parameters. Experimentation is carried out and the developed model is validated with the experimental results. Effects of various material and geometrical parameters are studied in the present paper. The present work can give insight in the process and can be helpful to the designers as well as to the researchers working in the area of metal forming. 相似文献
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《Journal of Manufacturing Processes》2000,2(4):258-269
Laser forming, a novel manufacturing method for bending sheet metal first reported in 1985, has been investigated as an alternative to hot brake forming (industry standard) of titanium sheet parts for the aircraft industry. Laser forming involves scanning a focused or partially defocused laser beam over the surface of a titanium workpiece to cause localized heating along the bend line and angular deflection toward the beam. The main advantage that laser forming has over conventional brake forming is increased process flexibility. An experimental investigation of this process (primarily designed experiments) met the following objectives: identified the response variables related to change in geometry (bend angle) and material microstructure; characterized the influence of process variables (scanning speed, beam diameter, laser power) on these response variables; determined the degree of controllability over the process variables; and evaluated the suitability of laser forming for the aircraft industry (most important), all with respect to titanium sheet. It has been determined that laser forming with an Nd:YAG laser is a controllable, flexible manufacturing process for titanium sheet bending. Unfortunately, these advantages over traditional hot brake forming are overshadowed by the fact that, with regard to forming with titanium, laser forming is significantly slower and more labor and energy intensive, and results in unacceptable material properties at the bend line according to aircraft industry standards. These findings cast doubt over the assertions of some researchers that laser forming may be a viable manufacturing process for parts made in small batches. Instead, it appears that it may be best suited for rapid prototyping of sheet metal parts. 相似文献
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Madhu Vadali Chao Ma Neil A. Duffie Xiaochun Li Frank E. Pfefferkorn 《Journal of Manufacturing Processes》2012,14(3):307-315
The objective of this work is to predict the final roughness of metal surfaces that have undergone pulsed laser micro polishing. The motivation for pulsed laser micro polishing is to reduce the surface roughness of parts whose surface texture can approach the feature size. Being able to predict the magnitude of the polishing and frequency (wavelength) content of the surface will assist in the design of optimal processing parameters with minimal experiments. Laser pulses are used to create shallow melt pools with a controlled size (e.g., depth) and duration in order to allow surface tension forces to “pull down” asperities with small radius of curvature. There is no ablation occurring in the process being modeled. The melt depth and duration are predicted with a transient, two-dimensional axisymmetric heat transfer model with temperature-dependent material properties. The surface of the melt pool is analytically modeled as oscillations of stationary capillary waves with damping resulting from the forces of surface tension and viscosity. Above a critical spatial frequency, fcr, a significant reduction in the amplitude of the spatial Fourier components is expected. The work described in this paper extends the concept of critical frequency to a physics-based prediction methodology for predicting the spatial frequency content and surface roughness after polishing, given the features of the original surface, the material properties, and laser parameters. The proposed prediction methodology was validated using line polishing data for stainless steel 316L and area polishing results for pure nickel, Ti6Al4V, and Al-6061-T6. The predicted average surface roughnesses were within 12% of the values measured on the polished surfaces. 相似文献
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