modelling and optimal design of sheet metal rp&m processes meelis pohlak rein küttner jüri...
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![Page 1: Modelling and optimal design of sheet metal RP&M processes Meelis Pohlak Rein Küttner Jüri Majak Tallinn University of Technology 2004](https://reader036.vdocuments.mx/reader036/viewer/2022062308/56649d9e5503460f94a893e8/html5/thumbnails/1.jpg)
Modelling and optimal design of sheet metal
RP&M processes
Meelis Pohlak Rein Küttner
Jüri Majak
Tallinn University of Technology
2004
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Outline
Objective What is Incremental Forming Simulation of the process Experimental study Optimization model
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Objectives
To study the mechanics of the process To analyze the limitations of incremental
forming process To study the influence of process and product
parameters to the properties of products To create models for process optimization
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Incremental Forming process
1. Tool moves step downwards;
2. Draws profile on horizontal plane;
3. Step downwards;
4. next profile, etc
Kim T. J., Yang D. Y., Improvement of formability for the incremental sheet metal forming process. International Journal of Mechanical Sciences 42 (2000), pp 1271-1286.
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Two types of Incremental Forming:
1. With support 2. Without support
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Some additional types of Incremental Forming:
1. Multistage or multiaxis forming
2. Forming using soft plastic support material
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Limitations of the process
Problems with steep walls Accuracy issues Better surface quality – longer processing time
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Phases of the simulation process
1. Building CAD models of product, blank and tool (SolidEdge)
2. Preparing toolpaths (SurfCAM)3. Preparing Finite Element model
(ANSYS)4. Solving model (ANSYS, LS-DYNA)5. Post processing (ANSYS)6. Validation
CAD
CAM
FEA
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Simulation Model
Loading Tool movement control Material models Element types
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Simulation Model
Loading
Tool movement control Coordinates from CAM software Several loadsteps
Material models Element types
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Simulation Model Loading Tool movement control
Material models Testing of material properties is essential Multilinear isotropic strain hardening
plasticity model was used Element types
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Simulation Model
Loading Tool movement control Material models
Element types 4 noded shell elements 8 noded shell elements Tool and support: rigid
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Process of simulation
Element size 1 mm and 2,5 mm in separate cases >2000 elements
Duration (CPU: 1,6 GHz Pentium 4) More than 70 hours with 2,5 mm elements and
20 step-down cycles (ANSYS) Similar model 26 hours with mass scaling
(LS-DYNA)
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Simulation
Simulation provides data for optimization Elements need to be smaller Simulations are very resource intensive
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Experimental study
Variables: Tool radius, R (Rmin= 3 mm; Rmax = 10 mm);
Step size, pz (pz min = 0,1 mm; pz max = 1 mm);
Wall draft angle, (min = 30º; max = 60º).
Measured parameters: Wall thickness; Flatness deviation of non-horizontal
walls; Surface roughness on processed
surfaces; Total form deviation of part.
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Experimental study: results
638,0163,0 s
ZZ pRpRFD 204,0024,0157,016,000284,0259,0
ZZZ pRRppRRa 15,4145,017,0319,0478,00932,02,1
ZZ ppRFMD 72,347,125,30466,047,6
•Thickness:
•Flatness deviation:
•Surface roughness:
•Form deviation:
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Experimental study: resultsStep size - form deviation relationship
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
7,500
0 0,2 0,4 0,6 0,8 1 1,2
Step size, pz (mm)
Fo
rm d
ev
iati
on
(m
m)
Form deviation (R=3;Alfa=30)
Form deviation(R=10; Alfa=30)
Form deviation (R=3;Alfa=60)
Form deviation(R=10; Alfa=60)
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Experimental study: resultsDraft angle - part thickness relationship
0,400
0,450
0,500
0,550
0,600
0,650
0,700
0,750
0,800
0,850
0,900
25 30 35 40 45 50 55 60 65
Draft angle
Pa
rt t
hic
kn
es
s (
mm
)
Thickness (R=3;pz=0,1)
Thickness (R=10;pz=0,1)
Thickness (R=3;pz=1)
Thickness (R=10;pz=1)
Sine law
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Process Optimization
satisfying constraints: min),,,,( fRpLTT z
,),,( FDpRFD z ,),,( aza RpRR
,),,( FMDpRFMD z ,maxmin
,maxmin RRR ,maxmin zzz ppp
maxmin fff
(Processing time)
(Flatness deviation)
(Surface roughness)
(Form deviation)
(Wall draft angle)
(Tool radius)
(Vertical step size)
(Feed rate)
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Conclusion
Accuracy of the forming process has to be improved
In process modeling in addition to linear relationships also interactions of the parameters have to be considered
Our study creates the basis for using response surface methodology for process optimization