finite element simulation of sheet metal forming - project report

8/12/2019 Finite Element Simulation of Sheet Metal Forming - Project Report

1/34

Finite element simulation of stretch forming

behaviour of four different processed

Mg alloy sheets

Thesis submitted in the fulfilment of the requirements for the award of the

degree of

BACHELOR OF TECHNOLOGY (HONS.)

IN

MECHANICAL ENGINEERING

BY

B.Venkata Sainath

Roll No: 10MF3IM05

Under the guidance of

Prof. S.K. Panda

DEPARTMENT OF MECHANICAL ENGINEEERING

INDIAN INSTITUTE OF TECHNOLOGY KHARAGPUR

JULY 2014


2/34

CERTICATE

This is to certify that the thesis entitled Finite element simulation of

stretch forming behaviour of four different processed Mg alloy sheets

submitted by Mr B. Venkata Sainath (10MF3IM05) to the Department ofMechanical Engineering, Indian Institute of Technology, Kharagpur, in partial

fulfilment for the award of degree of Bachelor of Technology (Hons.) is a bona

fide record work carried out by him under my supervision and guidance. This

thesis has fulfilled all the requirements as per the regulations of this Institute

and, in my opinion, has reached the standard needed for submission.

_______________________

Prof. S. K Panda

Department of Mechanical Engineering

IIT Kharagpur

.


3/34

DECLARATION BY STUDENT

I certify that

a) The work contained in this report has been done by me under theguidance of my supervisor.

b) The work has not been submitted to any other Institute for any degree ordiploma.

c) I have confirmed to the norms and guidelines given in the Ethical Code ofconduct the Institute.

d) Whenever I have used materials (data, theoretical analysis, figures andtext) from other sources, I have given due credit to them by citing them in

the text of report and giving their details in the references. Further, I have

taken permission from the copyright owners of the sources, whenever

necessary.

DATE: Signature of the Student

B.Venkata Sainath

10MF3IM05


4/34

ACKNOWLEDGEMENT

I would like to acknowledge and extend my heartfelt gratitude to my

guide, Prof. S. K Panda, Mechanical Engineering Department, Indian Institute

of Technology Kharagpur for guiding me through the entire course of the

project. Without his guidance, I would not have been able to complete my work.

I would like to extend my gratitude to research scholars Kaushik

Bandyopadhyay and Sudhy of the foundry lab, mechanical engineeringdepartment for their continuous support throughout my project.

Date:

B.Venkata Sainath

10MF3IM05

Department of Mechanical Engineering

IIT Kharagpur


5/34

Table of Contents

Chapter.1 ............................................................................................................... 8

1. Introduction:- ................................................................................................. 8

1.1 Stretch Forming: ....................................................................................... 9

1.2. Limiting Dome Height Test: .................................................................. 10

Chapter.2 ............................................................................................................. 12

2. Literature Review:- ...................................................................................... 12Chapter.3 ............................................................................................................. 14

3. Objectives:- .................................................................................................. 14

4. Methodology:- ............................................................................................. 15

4.1 STEP1 (Obtaining n, K and E values from the stress-strain graph):- .... 15

4.2 STEP2 (Finite element modelling and simulation of LDH test set up) 18

5. Results and Discussion:- .............................................................................. 22

5.1. Limiting Dome Height (LDH):- ............................................................ 22

5.2. Forming limit diagram (FLD):- ............................................................. 23

5.2.1. FLD obtained through Keeler-Brazier equation: ................................ 23

5.2.2. FLD obtained from simulation: .......................................................... 25

5.3. Thickness distribution:- ......................................................................... 28

5.3.1. Thickness distribution of TRC & rolled ZKQX alloy sheet: ............. 28

5.3.2 Comparison of Thickness distribution of ZKQX alloy sheets: ........... 29

Chapter.6 ............................................................................................................. 33

Conclusions:- ................................................................................................... 33

7. References :- ................................................................................................... 34


6/34

Table of Figures

Figure 1 Simple stretch forming process of a sample sheet ............................... 9

Figure 2 A schematic of the tool set-up for hemispherical limiting dome

height tests.[1] ..................................................................................................... 10

Figure 3 Engineering stress-strain diagrams of different ZKQX alloy sheets ... 15

Figure 4 Finite element modelling of limiting dome height set up

a) Front view b) Isometric view .......................................................................... 18

Figure 5 Simulation of the stretch forming of TRC & rolled alloy sheet .......... 20

Figure 6 Thickness distribution of the cup at the limiting dome height - top view

............................................................................................................................. 21

Figure 7 Comparison of FLDs of ZKQX alloy sheets obtained through

Keeler-Brazier equation ...................................................................................... 24

Figure 8 FLDs of all ZKQX sheets obtained through simulation ..................... 27

Figure 9 Thickness distribution of TRC & rolled ZKQX alloy sheet ................ 28

Figure 10 Comparison of thickness distribution of ZKQX alloy sheets ............ 30

Figure 11 Thickness distribution of ZKQX alloy sheets ................................... 31

Figure 12 Variation of minimum thickness of the cup along the curvilinear.....32

distance from the centre
http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507233http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507234http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507234http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507237http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507240http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507243http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507243http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507243http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507240http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507237http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507234http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507234http://c/Users/sainath/Downloads/btp%20finally%20doing--incomplete.docx%23_Toc392507233


7/34


8/34

Chapter.1

1. Introduction:-

Magnesium alloys are subjects of intensive research interest as potential

structural materials for weight reduction in transportation vehicles[1]. Currently

magnesium alloys are mainly used as cast products because of their excellent

castability. However, due to their limited formability and their low strength

compared to aluminium alloys, very few magnesium alloys are used as wrought

products. High-strength sheet alloys should find use in many applications, not

only for automotive applications but also for lightweight casing of electronic

products. The ability of plastic deformation of the magnesium alloys is poor.

Therefore, the conventional production process of the magnesium alloy strips

takes many steps, including multi-hot rolling and multi-heat- treatment, which is

long and needs high energy cost. By the twin-roll casting, the magnesium alloy

cast strip with thickness ranging from 2mm-8mm can be produced and then be

rolled to the needed thickness, which is a highly effective, time-saving, and

energy saving process.

Many magnesium alloys were casted recently using this twin roll casting

technology. The TRC Mg2.4Zn3Al0.3Mn alloy sheet with a T6D heat

treatment (solution treatment and double ageing) showed a tensile yield strength

of about 319 MPa with an elongation to failure of 6.3%. This yield strength is

significantly higher than that reported for the conventionally rolled AZ31 (Mg

3Al0.5Zn (at.%)) (235 MPa). It was reported that reported that trace additions

of Ag and Ca enhanced the age hardening of MgZn alloys.


9/34


10/34

For the simple stretch forming process, the sheet sample which has to be

formed, is clamped between two gripping jaws located on opposite ends, see

Figure 1.The forming tool or block is fixed on to a tool table which can be

moved hydraulically in a vertical direction. The forces necessary for the

forming are transferred through the form block to the sheet sample. The part to

be formed receives its contours during the motion of the forming block, the

gripping jaws remaining stationary.

1.2. Limiting Dome Height Test:

It is a method to evaluate the formability of a sheet metal. In this test, the

sheet sample is firmly clamped between the two gripping jaws located on

opposite ends and is stretched by a hemispherical punch in transverse direction

as shown in figure 2. During the motion of the forming block, the blank sheet

receives its contours.

Figure 2 A schematic of the tool set-up for hemispherical limiting

dome height tests.[1]


11/34

Due to the large area of contact between the hemispherical punch and the

blank, the frictional forces prevent a deformation of the sheet in this region.

This is especially true for flat shapes where even a small motion of thehemispherical punch is sufficient to allow a large part of the blank to "hug" the

punch.

A further motion of the hemispherical causes the sheet blank to be

strained, but mainly in the region of the frame. Due to the frictional forces

acting between form block and blank, the middle regions hardly undergo any

deformation, i.e., the maximum possible straining capacity of the sheet is notattained. This means that the maximum attainable theoretical elongation,

calculated on the basis of the length of blank between the gripping jaws, cannot

be attained, since the middle regions of flat shapes are hardly deformed and,

therefore, do not contribute much to the total deformation strain. The sheet

material flows under the tensile stress only out of the sheet thickness, so that the

surface of the sheet expands. When the hemispherical punch reaches critical

depth, cracking of sheet metal occurs. The greatest depth that the blank can

withstand under the pure stretching of the hemispherical punch without crackingis called limiting dome height. This is a standard measurement of stretchability.


12/34

Chapter.2

2. Literature Review:-

Magnesium alloys are promising structural light materials due to their

high specific strength, high specific stiffness, and so on. The use of Mg alloys is

expanding, particularly in automobile industry and consumer electronics

industry and. For their greater applicability, forming technology for high-

performance Mg alloy sheets should be developed. Deformation modes of Mg

crystals are mainly the (0001) (1120) basal slip, the prismatic slip,

the pyramidal slip, the second-order pyramidalslip and the twinning. Because the critical resolved shear stresses

for non-basal slips are higher than that for a basal slip near room temperature,

formability of Mg alloys strongly depends on texture. Additionally, since rolled

Mg alloy sheets show strong basal texture and, rolled Mg alloy sheets often

exhibit low press formability at near room temperature.

Recently, twin roll casting (TRC) has been applied to magnesium alloys toreduce the strong basal texture and grain size. So far, only a few heat-treatable

TRC alloys, such as Mg2.4Zn0.3Mn (at.%) and Mg2.4Zn(13)Al0.3Mn

(at.%) alloys have been reported [6]. The TRC Mg2.4Zn3Al0.3Mn alloy

sheet with a T6D heat treatment (solution treatment and double ageing) showed

a tensile yield strength of about 319 MPa with an elongation to failure of 6.3%

[6]. This yield strength is significantly higher than that reported for the

conventionally rolled AZ31 (Mg3Al0.5Zn (at.%)) (235 MPa).


13/34


14/34

Chapter.3

3. Objectives:-

The objective is to study the stretch formability of four different

processed Mg alloy sheets by finite element simulation to get insight into the

influence of pre processed conditions on formability and hence automotive

industries will select the suitable manufacturing process for the production of

Mg alloy sheet metals.

These four different processed sheets are:

(i) Twin roll casted (TRC) and rolled ZKQXsheet

(ii) Twin roll casted (TRC) and heated ZKQXsheet

(iii) Ingot casted and extruded ZKQXsheet

(iv) Ingot casted, extruded and heat treated ZKQXsheet

Hence the following are the specific objectives of the present study:

1. To develop finite element (FE) model of limiting dome height (LDH) test to

evaluate formability of the four different processed Mg alloy sheets.

2. To predict failure during stretch forming by incorporating forming limit

diagram (FLD) of all the four different processed Mg alloy sheets.

3. To predict and compare thickness distribution in stretch formed cups for all

the four different processed Mg alloy sheets.


15/34

Chapter.4

4. Methodology:-

4.1 STEP1 (Obtaining n, K and E values from the stress-strain graph):-

Engineering stress-strain diagrams of the ZKQX alloys sheets having

undergone different forming processes plotted in the same graph are obtained

from the literature review as shown in figure2.

Figure 3 Engineering stress-strain diagrams of different ZKQX alloy sheets


16/34

Engineering stress-strain data has been collected for each of the curve

in the above figure using plot digitizer software. Engineering stress and

engineering strain are converted into true stress and true strain using the

following standard equations (1) and (2).

ln( ......(1)

= ( ......(2)

Where = true stress, = engineering Stress ,

= true Strain , engineering Strain

The relationship between stress and strain in the plastic region (between

yield point and UTS) of the true stress-true strain diagram is given by the

Hollomons equation(3) as follows:

= K......(3)

where = true stress

K = strength coefficient

= true Strain n = strain-hardening exponent

The value of n lies between 0 and 1. A value of 0 means that a material is a

perfectly plastic solid, while a value of 1 represents a 100% elastic solid. Most

metals have an n value between 0.10 and 0.50.

The equation (3) can be converted to linear form by taking logarithm on both

sides as follows

( + ......(4)

True Stress and true strain data is plotted on log-log graph and K and n

values are obtained for each of the curve. Youngs modulus(E) for each of the

curve is also calculated by collecting the data on the linear portion of the

engineering stress-strain diagram. The values of theses mechanical properties

(n, K and E values) are provided in table 1.


17/34

Table 1: strain hardening exponent (n), strength coefficient (K) and Youngs

modulus (E) of four different processed ZKQX alloy sheets

Sl.No ZKQX alloy n

value

K (MPa)

value

E(Youngs

modulus in

GPa)

1 TRC & rolled 0.22 490.9 42.3

2 TRC & Heat Treated 0.07 444.6 34.8

3 Extruded 0.11 503.5 34.8

4 Extruded & Heat Treated 0.09 480.3 34.8


18/34

4.2 STEP2 (Finite element modelling and simulation of LDH test set up)

Different tools used in limiting dome height test such as die, binder,

tool and draw bead are modelled in the eta/DYNAFORM version 5.7.1 softwarealong with the blank as shown in figure 4. Quarter model has been employed for

modelling and simulation because of less computational time. Two different

views of the model (X-Z view) front view and isometric view of the model are

shown in figure 3.The detailed geometrical properties used for the modelling are

mentioned in the table 2.

a) Front view of FE modelling b) Isometric view of FE modelling

Figure 4 Finite element modelling of limiting dome height set up

a) Front view b) Isometric view

Table 2: Geometrical properties considered for FE modelling

Sl.No Parameter Size(mm)

1 Thickness of the blank 1.2

2 Radius of the blank 47.4

3 Inner radius of the die, binder 27

4 Outer radius of the die, binder 90

5 Radius of the hemispherical punch 25

6 Radius of the draw bead 36

7 Corner radius of the die 10


19/34

The designed model as shown in the above figures has been analysed

using LS-DYNA Program manager and simulated in ETA/post-processor 1.8.0

using material properties of the blank such as (n) strain-hardening exponent, (K)

strength coefficient and E (Youngs modulus). Simulation has been carried out

for all the four different types of alloy blank sheets. Many parameters were

assumed during the simulation.

Parameters assumed in the simulation:

1. Tooling such as die, binder, punch, draw bead are rigid bodies and blankis deformable.

2. Static friction between the die and the blank is equal to 0.1.3. Static friction between the punch and the blank is equal to 0.1.4. Poissons ratio of all the alloys is 0.29.5. Binder force applied on the blank is 5000N.6. Von-Mises criterion is used as failure criteria for the blank.7. Stroke distance is 30mm.8. Stretching is considered to be symmetric along x-z and y-z planes.

Simulation for all the blanks has been carried in 150 steps and some of

these intermediate steps are shown in the figure 5. Limiting Dome Height is

obtained by measuring the height of the cup at one step before onset of

cracking. Forming limit diagrams are also obtained for each of the sheets and

the results have been discussed in section 5.2.

Thickness of the cup at various nodes at the limiting dome height has been

calculated as shown in the figure 6 and curvilinear distance of these points from

the centre of the cup is measured. Using this data, variation of the thickness of

the cup at the limiting dome height has been plotted against the curvilinear

distance from the centre of the cup.


20/34


21/34

Figure 6 Thickness distribution of the cup at the limiting dome height - top view


22/34

Chapter.5

5. Results and Discussion:-

5.1. Limiting Dome Height (LDH):-

It is the greatest depth that a material can withstand under the pure

stretching of a hemispherical punch .This is a standard measurement of

stretchability. LDH values of all the four sheets obtained from the simulation

are mentioned in Table 3.

Table 3: LDH values of different ZKQX alloy sheets

Sl.No ZKQX alloy n value UTS(M Pa) Yield

strength(M Pa)

LDH(mm)

1 TRC & rolled 0.22 285 177 25.17

2 TRC & HeatTreated

0.07 342 320 15.53

3 Extruded 0.11 352 305 19.30

4 Extruded &

Heat Treated

0.09 360 325 16.98

It is observed that TRC & rolled ZKQX sheet shows higher value of

limiting dome height of 25.17 mm compared to other sheets. Generally LDH

increases with decrease in yield strength. If yield strength is low, material starts

undergoing plastic deformation at an earlier stage. Since TRC & rolled ZKQX

sheet has very low yield strength value (177 M Pa) compared to other sheets, it

has shown exceptionally higher value of LDH or formability.

Extruded ZKQX sheet has shown LDH of 19.31 mm, higher than that of

TRC & heat Treated and extruded & heat treated ZKQX sheets because its yield

strength of 305MPa, slightly lower than that of them. LDH values of TRC &

heat treated sheet and extruded and heat treated sheet are close because their

yield strength values are close.


23/34

Though extruded and heat treated ZKQX sheet has slightly higher yield

strength than TRC & heat treated alloy, it has higher LDH. The reason for this

can be extruded & heat treated alloy has a wider plastic zone (between yield

strength and UTS) than the TRC & heat treated alloy.

The order of formability of sheets based on LDH values is as follows:

TRC & rolled > Extruded > Extruded and Heat treated > TRC & Heat treated

5.2. Forming limit diagram (FLD):-

5.2.1. FLD obtained through Keeler-Brazier equation:

FLDs for all the ZKQX alloy sheets were drawn by calculating

(Plain-strain intercept) using KeelerBrazier equation:

(%) = (23.3+ 14.3*t)(n/0.21) ......(5)

Where t= initial thickness of the strip in mm

n= strain-hardening exponent

and sliding the Goodwin and Keeler Forming limit diagram downwards along

the major engineering strain axis by distance equal to the difference between

of the Goodwin and Keeler Forming limit diagram (43.3%) and of

the respective sheet calculated from the above equation. These values are given

in table 4.


24/34

Table 4: values of ZKQX alloy sheets

Sl.No ZKQX alloy Thickness (mm)

1 TRC & rolled 1.2 42.4

2 TRC & Heat treated 1.2 13.4

3 Extruded 1.2 21.5

4 Extruded and Heat

treated

1.2 16.3

FLDs of all the ZKQX alloy sheets obtained using Keeler-Brazier

equation are shown in the figure8.

Figure 7 Comparison of FLDs of ZKQX alloy sheets obtained throughKeeler-Brazier equation

0

20

40

60

80

100

120

140

160

180

200

-80 -60 -40 -20 0 20 40 60 80

MajorE

ngineeringStrain,%

Minor Engineering Strain,%

FLD of ZKQX alloy sheets

extruded and heat treated

Extruded

TRC

TRC and heat treated


25/34


26/34

Forming limit diagrams obtained from the simulation are shown in the

figure .Their values are estimated using Plot Digitizer and are compared

with that of the values obtained theoretically using Keeler-Brazier equation in

the table5.

Table5: Comparison of values obtained theoretically and from simulation

Sl.No ZKQX alloy %(eng.strain)

%(True strain)

theoretical

%(True strain)

-simulation

Error

(%)

1 TRC &

rolled

42.4 35.3 35.2 0.43

2 TRC and

heat treated

13.4 12.6 12.7 -0.64

3 Extruded 21.5 19.5 19.3 1.03

4 Extruded

and heat

treated

16.3 15.1 14.9 1.66

The values obtained from the simulation and form the Keeler-

Brazier equation are very close to each other. The reason for the minute

difference might be in collecting data using plot digitizer.


27/34

FLD of TRC ZKQX sheet FLD of TRC and Heat treated

ZKQX sheet

FLD of extruded ZKQX sheet FLD of extruded and heat

treated ZKQX sheet

Figure 8 FLDs of all ZKQX sheets obtained through simulation


28/34

5.3. Thickness distribution:-

5.3.1. Thickness distribution of TRC & rolled ZKQX alloy sheet:

Thickness at various points along the cup has been obtained at the

limiting dome height for all the ZKQX alloy sheets form the simulation. The

displacement between the successive points has been measured and it is

assumed to be equal to the curvilinear distance between them. Using this data,

distribution of thickness along the curvilinear distance from the centre of the

cup is plotted as shown in figure 9.

Figure 9 Thickness distribution of TRC & rolled ZKQX alloy sheet

0

0.2

0.4

0.6

0.8

1

1.2

1.4

0 10 20 30 40 50 60

Thicknessofthe

cup(mm)

Curvilinear distance from the centre of the cup(mm)

Series1


29/34

It can be observed that thickness first decreases till 15.1mm from the

centre of the cup and then increases till the flange region and attains a constant

value. It can also be observed that maximum thinning occurred at the punch

corner with a thickness value of 0.6 mm and maximum thickness occurs at the

flange region.

This is because the blank receives its contours during the motion of the

punch, the gripping jaws remaining stationary. At the beginning of the stroke,

the sheet blank first drapes itself around the form block, following its contours.

Due to the large area of contact between form block and the blank, the frictional

forces prevent maximum deformation of the sheet in centre region and a further

motion of the punch causes the sheet to be strained mainly in the region near the

punch corner. Draw bead which is used to control the flow of the sheet into die

cavity is responsible for the constant thickness of the cup around 41mm distance

from the centre.

5.3.2 Comparison of Thickness distribution of ZKQX alloy sheets:

Thickness variation of the cup for all the alloy sheets is observed to

follow the same pattern as that of TRC and rolled alloy. However, there are

significant differences in the minimum thickness values obtained and the

elongation of the sheet (measured as curvilinear distance from the centre of the

cup to corner of the flange portion).Thickness distribution of all ZKQX alloy

sheets has been plotted in the figure 10 and simulation results of thickness

distribution of the sheets at limiting dome height are shown in figure 11.

Minimum thickness value and elongation of the sheets has been calculated andcompared in the table6. It can be observed from figure 10 that minimum

thickness of the cup occurs at different distances from the centre of the cup.

This variation of the minimum thickness of the cup with the curvilinear distance

from the centre of the cup has been plotted in figure 12.


30/34

Figure 10 Comparison of thickness distribution of ZKQX alloy sheets

Table 6: Minimum thickness of the cup and elongation of ZKQX alloy sheets

Sl.No ZKQX alloy Minimum

thickness

(mm)

Elongation(mm) n value

1 TRC & rolled 0.60 9.68 0.22

2 TRC & heat treated 0.83 3.62 0.07

3 Extruded 0.73 5.66 0.11

4 Extruded and heat

treated

0.79 4.44 0.09

0

0.2

0.4

0.6

0.8

1

1.2

1.4

0 10 20 30 40 50 60

Thic

knessofthecup(mm)

Curvilinear distance from the centre of the

cup(mm)

TRC and rolled

TRC and heat treated

Extruded

Extruded and heat treated


31/34

TRC & rolled TRC & Heat treated

Extruded Extruded and Heat treated

Figure 11 Thickness distribution of ZKQX alloy sheets


32/34

Figure 12 Variation of minimum thickness of the cup along the curvilinear

distance from the centre

Fig 11 shows the thickness distribution of all ZKQX alloy sheets. It can

observed that blank become thicker at outer portions and thinner ant the punch

corner .As the punch forces blank into die cavity, the blank diameter decreases

and causes the blank to become to thicker at its outer portion due to

circumferential compressive stresses to which the material material elements inthe outer portion is subjected to.

Thickness distribution of all ZKQX alloy sheets has been plotted in

figure 11. It can be observed that TRC & rolled sheet has the lowest value of

minimum thickness (0.60mm) and highest elongation (9.68mm) compared to

other alloy sheets where as TRC & heat treated alloy has the highest value of

minimum thickness (0.83mm) and lowest elongation (3.616mm).The reasonsfor these variations among the sheets are due to differences in yield strength

value and same as that of limiting dome height (LDH).

The order of formability of sheets based on elongation and minimum thickness

value of the cup is as follows:

TRC > Extruded > Extruded and Heat treated > TRC & Heat treated

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0 2 4 6 8 10 12 14 16

Minimumthickn

essofthe

cup(mm

)

Curvilinear distance from the centre of the axis (mm)


33/34

Chapter.6

Conclusions:-

Finite element modelling and simulation of the four different processed

magnesium alloys has been successfully done.

1. The TRC & rolled ZKQX alloy sheet is found to have much higher limiting

dome height than ingot cast ZKQX alloy sheets because its n value is much

higher than the others.

2. value of the TRC & rolled ZKQX alloy sheet is found to much higher

than ingot cast ZKQX alloy sheets which means that it can undergo more

thinning and stretching than the other alloy sheets.

3. Failure location (minimum thickness) and thickness distribution of all the

four different processed ZKQX alloy sheets has been obtained.

Hence, automobile industries should use TRC and rolled ZKQX alloy

than ingot cast ZKQX alloy sheets for better formability and for better

automotive applications.


34/34

finite element simulation of sheet metal forming - project report

Documents