Numerical analysis of hot deep drawing of din 27MNCRB5 steel sheets under controlled stretching

Hot stamping has been widely studied and increasingly applied in the automotive industry. This process is characterized by its ability to stamp high strength steels, yielding products with high mechanical strength, thus reducing the weight of stamped components and therefore the vehicles weight. It also demands less energy because steel sheets are heated by induction, more efficient than electric furnaces. With controlled stretching it is possible to manufacture thinner stamped parts with high mechanical strength, therefore it is necessary to know the formability limits to prevent failure and achieve the largest possible thickness reduction. In this work the hot formability of DIN 27MnCrB5 steel sheets under stretching conditions was evaluated by numerical simulation with the finite element software Forge2008. The numerical results were compared to experimental results. Initially hot tensile tests were simulated to define the strain rate in different regions of the sample and to evaluate the deformation at fracture. For tests at 700, 800 and 900ºC it was found that the strain rates vary from 0.01 to 0.5 s-1. Experimental tensile tests were also carried out with the same conditions as simulated. Both simulation and experiments presented very similar results for the ultimate tensile strength, and therefore it was possible to assume the experimental fracture strain as a consistent input for the numerical models. With the results of the tensile tests, hot Nakazima tests were simulated to evaluate the highest dome which could be formed without failure risks caused by sheet thickness thinning. The simulation results were validated by experimental tests, and as a result, a new numerical strategy was elaborated to define the hot formability based on the plastic instability and necking localization as a function of the stamping temperature and blank dimensions

Recent Approaches for the Manufacturing of Polymeric Cranial Prostheses by Incremental Sheet Forming

This paper presents recent research experiences developed with the aim of manufacturing cranial prostheses in polymeric sheet using Incremental Sheet Forming (ISF) technologies. With this purpose, different approaches have been carried out in Single-Point Incremental Forming (SPIF) and Two-Point Incremental Forming (TPIF) in order to produce customized cranial implants using different polymeric materials. In this context, this research work provides a methodology to design and manufacture polymer customized cranial prostheses using the ISF technologies starting from a patient’s computerized tomography (CT). The results demonstrate the potential of manufacturing polymeric cranial prostheses by ISF in terms of the high formability achievable and show the appropriate geometrical accuracy at affordable manufacturing costs provided by these processes.Ministerio de Economía y Competitividad DPI2015-64047-

The FLC, enhanced fromavbility, and incremental sheet forming

The FLC is a well known concept in the sheet metal forming world. It is used to map the material’s formability and the make-ability of a product. The FLC is valid only within certain restrictions. These restrictions are: A: a straight strain path; B: absence of bending; C: absence of through-thickness shear; D: a condition of plane stress.\ud The formability of a material can be increased significantly if one is allowed to violate any of these restrictions, meaning either: use a complex strain path, incorporate bending, incorporate through-thickness shear, or apply a contact stress. Both shear and contact stress change the stress state, and both lower the yield stress in tension and raise the necking limit up to a certain level. Bending creates a non-uniform stress distribution over the thickness of the sheet, resulting in a reduction of the yield force in tension, and it creates a range of stable elongation depending on the sheet thickness at each passage of the punch. The effect of a complex strain path depends on the particular situation; in incremental sheet forming it is based on non-isotropic hardening.\ud In general it will not be possible to create such conditions in the entire product at once. However it is possible to do this intentionally in a small, restricted zone by creating special situations there. By moving this zone over the entire product the whole part can be made with increased formability. This technique of incremental forming is explained briefly. The special conditions around the punch indeed violate the FLC restrictions mentioned above. The enhanced formability obtained in incremental sheet forming is illustrated with many examples

An Investigation, Using Standard Experimental Techniques, to Determine FLCs at Elevated Temperature for Aluminium Alloys

An experimental procedure has been developed for the determination of FLCs at elevated temperatures. The GOM ARGUS system was employed for measuring surface strain based on pre-applied grids (pattern), and limit strains were determined according to the ISO 12004-2:2008 standard. Forming limit curves (FLCs) have been determined for AA5754 under warm forming conditions in an isothermal environment. The tests were carried out at various temperatures up to 300oC and forming speeds ranging from 5 – 300 mm s-1 . Results reveal the significant effect of both temperature and forming speed on FLCs of AA5754. Formability increases with increasing temperature above 200oC. Formability also increases with decreasing speed. The presented FLC results show that the best formability exists at low forming speed and the high temperature end of the warm forming range

Deep drawing simulations of Tailored Blanks and experimental verification

Tailored Blanks are increasingly used in the automotive industry.\ud A combination of different materials, thickness, and coatings can be welded\ud together to form a blank for stamping car body panels. The main advantage\ud of using Tailored Blanks is to have specific characteristics at particular parts\ud of the blank in order to reduce the material weight and costs.\ud To investigate the behaviour of Tailored Blanks during deep drawing, the\ud finite element code DiekA is used. In this paper, simulations of the deep\ud drawing of two products using Tailored Blanks are discussed. For\ud verification, the two products are stamped to gain experimental information.\ud The correlation between the experimental results and the simulation results\ud appears to be satisfactory

Contact effects in bending affecting stress and formability

If a strip is pulled over a curved tool there is a contact stress acting on the strip. This contact stress changes the stress state in the material, which is analysed with a simple model. One effect is that the yield stress in tension is reduced. Predictions by the model agree with observation from a 90-degree bending test found in literature, and indirectly with observation from a stretch-bend test also found in literature. Another effect is that a change in stress state also affects the formability. This is analyzed by applying the maximum force condition on this situation. The predictions agree with a more thorough analysis of the effect of thickness stress in general, but the predictions of both methods are lower than actually observed in tests. There may be other mechanisms at work, and one candidate is presented

Formability evaluation of double layer circular tube as a device with energy absorption capacity

Recently, earthquakes frequently occur in Japan. It is desired to promote seismic isolation technology of building. It has been found that newly designed composite material filled with low rigidity material to high rigidity material has significant energy absorbing capacity. However, it must have higher energy absorption capacity in order to respond to a large scale earthquake. Therefore, we have proposed an energy absorbing device with a double layer circular tube as a cell. In previous work, it has been shown that hysteresis occurs and absorbs the energy by friction that is generated between the outer layer and the inner layer. It is effective when inside shape of inner layer is defined as floral pattern. In this study, we considered to form the inner layer circular tube by forward and backward extrusion and to assemble with the outer layer circular tube at the same time. After forming, it is necessary to generate hysteresis around the entire circumference of the circular tube. Ideally, the inner layer circular tube is tightened to the outer layer circular tube. In this research, it was aimed to know the contact state between the outer layer and the inner layer after forming. Therefore, the influence of the presence or absence of the outer layer circular tube on formability was investigated. As a result, there was a tendency for large elastic strain to remain at the contact portion between the circular tubes when the outer layer circular tube was set. This means that the outer layer circular tube hinders elastic recovery of the inner layer circular tube. Therefore, it was confirmed that the inner layer circular tube was tightened by the outer layer circular tube. The same result was obtained when the inner shape of the inner layer circular tube was a flower pattern

Optimization of conventional spinning process parameters by means of numerical simulation and statistical analysis

Research in sheet metal spinning has increased due to a greater demand, especially in the transportation industries, for parts with very high strength-to-weight ratios with low cost. Spinning processes are efficient in producing such characteristics and there is great flexibility in the process with a relatively low tool cost. The objectives of this investigation are to define the critical working parameters in spinning, show the effects of these factors on product quality characteristics, and to optimize the working parameters. The example used is the conventional spinning of a cylindrical cup. Optimization of the process is undertaken through the use of statistical analysis tools applied to the data produced from three-dimensional finite element simulations of the process. This has been achieved by generating two ‘designs of experiments’.The first identifies the most critical parameters for product formability and the second shows how these critical parameters affect the product quality. The results show that feed rate,relative clearance, and roller nose radius are the most important working parameters and significantly affect average thickness, thickness variation, and springback of the cylindrical cup. An additional 22 per cent improvement in the product quality characteristic is gained through using the optimum working parameters