Simulation of channel forming based on ABAQUS.docx

Simulation of channel forming based on ABAQUS.docx

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SimulationofchannelformingbasedonABAQUS

SimulationofchannelformingbasedonABAQUS

1257747MiaoYu

Abstract

Duringthedevelopmentofmanufacturingprocessing,themainproblemtothemolddesignerislongerdesigntime,especiallyforsomecomplexsheetmetalformingparts.TheinvitedanddevelopmentofsheetmetalformingCAEtechnologyandforminganalysissoftware,effectivelyreducethetimeofdesign,greatlyreducethetesttime,helpdesignertoimproveproductquality,reduceproductioncost.Sheetmetalformingistousemoldsforsheetmetalstampingprocessing,toformlightmass,smoothlysurface,beautifuloutlookingproduct.Ithasadvantagesofsavingmaterial,highefficiencyandlowcost.Itiswidelyusedinsuchasautomotive,aerospace,moldindustryarea.Thisarticle,useABAQUStosimulatethechannelforming,learnhowCAEsoftwarecaneffectivelyreducethetimeofdesignandanalysishowradius,coefficientoffrictionbetweentheblankandthedie,blankholderforceeffectonstressdistributionandpunchforce.

Keyword:

CAEABAQUSChannelforming

Introduction

Sheetmetalformingprocessistogiveaforceonthesheetmetalbymold,makethesheetmetaltoproduceplasticpermanentdeformation,inordertoobtainthedesiredproductshape.Inthisprocess,therehavemanyissuescanaffectthedeformationofsheetmetalanditishardtocontrolthedeformationshape.[1]

First,whengivethemetalanexternalforce,itwilldeformed,thedeformationcanbedividedintotheelasticdeformationandplasticdeformation,elasticdeformationisreversible,whenremovetheexternalforceafterdeformation,itwillreplacedtoitsoriginalshape.Second,thecompositionandorganizationofmetalhasagreateffectondeformation.Thirdly,thecoefficientoffrictionalsoeffectondeformation.So,itisveryhardtoanalysiswhatwillhappenedduringdeformationforindustryuntilCAEtechniquehadbeeninvited.[1][2]

Computeraidedengineeringisbasedonengineeringandscience,setupmodelandsimulateonacomputer.Ontheonehand,theapplicationofCAEtechnology,solvemanycomplexproblemsthatcannotbeanalysisinthepast.Ontheotherhand,itmakesalotofcomplexengineeringanalysisproblemsbecomesimplified,savealotoftime,avoidtherepeatedwork,letengineeringanalysisbecomefasterandaccurateandalsosavehugeofmoneyfromindustry.Itisveryimportantduringproductdesign,productanalysisandnewproductresearchanddevelopment.Now,withthedevelopmentofCAEtechnology,itisalreadybecomeanessentialtooltotheindustry.

ABAQUSispowerfulengineeringsimulationsoftwareofthefiniteelement,itcannotonlyanalysissimplelinearproblemsbutalsoanalysismanycomplexnon-linearproblems.ABAQUS,includingarich,cansimulatearbitrarygeometrycelllibrary.Andithasamateriallibrarythathasvarioustypesofmaterials.Asgeneralpurposesimulationsoftware,itcananalysisalmostallkindofengineeringproblems.[2][3][4]

Inthisarticle,useABAQUStosimulatethechannelforming,learnhowCAEsoftwarecaneffectivelyreducethetimeofdesignandanalysishowradius,coefficientoffrictionbetweentheblankandthedie,blankholderforceeffectonstressdistributionandpunchforce.

Experimentalandresult

First,accordingtoABAQUSExample4,whendieradiusequalto0.005,thecoefficientoffrictionbetweentheblankandthedieequalto0.1andtheblankholderforceequalto440,thestressandstraindistributionsandpunchforcecurveshowsbelow:

Forcecurve

Straindistribution

Stressdistribution

Second,changethedieradiusto0.003,thentheresultshowsbelow:

Forcecurve

Straindistribution

Stressdistribution

Third,changethedieradiusto0.007,thentheresultshowsbelow:

Forcecurve

Straindistribution

Stressdistribution

Fourth,keepdieradiusequalto0.005,changecoefficientoffrictionto0.05,theresultshowsbelow:

Forcecurve

Straindistribution

Stressdistribution

Fifth,changecoefficientoffrictionto0.015,theresultsshowsbelow:

Forcecurve

Straindistribution

Stressdistribution

Sixth,changecoefficientoffrictionto0.2,theresultsshowsbelow:

Forcecurve

Straindistribution

Stressdistribution

Seventh,keepdieradiusequalto0.005,coefficientoffrictionequalto0.1,changeblankholderforceto420,theresultshowsbelow:

Forcecurve

Straindistribution

Stressdistribution

Eighth,changeblankholderforceto460,theresultsshowsbelow:

Forcecurve

Straindistribution

Stressdistribution

Ninth,changeblankholderforceto480,theresultshowsbelow:

Forcecurve

Straindistribution

Stressdistribution

Discussion

1.Dieradiuseffectsformingprocess.

1.1Dieradiuseffectsstressdistribution.

Stressdistribution（r=0.003）

Stressdistribution（r=0.005）

Stressdistribution（r=0.007）

Pictureaboveshowsthestressdistributionaccordingtodifferentdieradius.Intherightpartofblank,whendieradiusesbecomelarger,thestressbecomeslarger.Intheleftpartofblank,whendieradiusincreased,thestressbecomessmaller.Frompictureabove,thestressisverysmallonleftorrightpartofblank.Thepartofblankrelatedtodieradiushasthelargestdifferentwhenchangeradius.Whendieradiusbecomelarger,thepartofblankrelatedtodieradiuswillbecomeveryweak,duringtheusageofthisworkpiece,thiswillbrokefirst.

1.2Dieradiuseffectpunchforce.

Forcecurve（r=0.003）

Forcecurve（r=0.005）

Forcecurve（r=0.007）

Pictureaboveshowstheforcecurveaccordingtodifferentdieradius.Fromthesepictures,whenr=0.003,themaximumforce=0.185*1e6,whenr=0.005,themaximumforce=0.18*1e6,whenr=0.007,themaximumforce=0.175*1e6.So,whendieradiusesbecomelarger,theforcewillbecomesmaller.

2.Coefficientoffrictioneffectformingprocess.

2.1Coefficientoffrictioneffectstressdistribution.

Stressdistribution（coefficient=0.015）

Stressdistribution（coefficient=0.05）

Stressdistribution（coefficient=0.1）

Stressdistribution（coefficient=0.2）

Pictureaboveshowsstressdistributionaccordingtodifferentcoefficient.Intherightpartofblank,whencoefficientbecomeslarger,thestressreducedfirst,thenincreased.Whencoefficientequalto0.1,ithasthesmalleststress.

Intheleftpartofblank,whencoefficientincreased,thestressslightlyincreased,whencoefficientequalto0.2,ithasthelargeststress.Thestressdistributiononpartofblankfacetodieradiushasbeenincreasedwhencoefficientincreased.Thestressdistributiononpartofblankfacetopunchincreasedfirst,thenbecomessmaller,thenincreasedagain.

2.2Coefficientoffrictioneffectpunchforcecurve

Forcecurve（coefficient=0.015）

Forcecurve（coefficient=0.05）

Forcecurve（coefficient=0.1）

Forcecurve（coefficient=0.2）

Figureaboveshowsforcecurveaccordingtodifferentcoefficient.Themaximumforceiswhencoefficient=0.2,force=0.29*1e6.Sowhencoefficientincreased,forceincreased.

3.Blankholderforceeffectformingprocess.

3.1Blankholderforceeffectstressdistribution.

Stressdistribution（f=420）

Stressdistribution（f=440）

Stressdistribution（f=460）

Stressdistribution（f=480）

Figuresaboveshowsstressdistributionaccordingtodifferentblankholderforce.Inthesefigures,itclearshowsthatwhenblankholderforceincreased,thestressdistributionontherightpartofblankdecreasedfirst,thenincreased.Thestressdistributionontheotherpartdoesnotchange.Thismeansthattheblankholderforcecannoteffectstressdistribution.

2.2Blankholderforceeffectpunchforcecurve.

Forcecurve（f=420）

Forcecurve（f=440）

Forcecurve（f=460）

Forcecurve（f=480）

Figuresaboveshowsforcecurveaccordingtodifferentblankholderforce.Whenf=420,themaximumforce=0.165*1e6.Whenf=440,themaximumforce=0.175*1e6.Whenf=460,themaximumforce=0.185*1e6.Whenf=480,themaximumforce=0.19*1e6.So,whenblankholderforceincreased,thepunchforceincreased.

Conclusion

Sheetmetalformingprocessistogiveaforceonthesheetmetalbymold,makethesheetmetaltoproduceplasticpermanentdeformation,inordertoobtainthedesiredproductshape.Duringthedevelopmentofmanufacturingprocessing,themainproblemtothemolddesignerislongerdesigntime,especiallyforsomecomplexsheetmetalformingparts.TheinvitedanddevelopmentofsheetmetalformingCAEtechnologyandforminganalysissoftware,effectivelyreducethetimeofdesign,greatlyreducethetesttime,helpdesignertoimproveproductquality,reduceproductioncost.Inthisarticle,useABAQUStosimulatethechannelforming,learnhowCAEsoftwarecaneffectivelyreducethetimeofdesignandanalysishowradius,coefficientoffrictionbetweentheblankandthedie,blankholderforceeffectonstressdistributionandpunchforce.Theresultshowsthatdieradius,coefficientoffrictionbetweentheblankandthedie,theblankholderforcehaveagreateffectonthisformingprocess.

References

[1]M.Kleiner,M.Geiger,andA.Klaus,ManufacturingofLightweightComponentsbyMetalForming,Ann.CIRP,2003,52

（2）,p521–542

[2]P.ChenandM.Koc,SimulationofSpringbackVariationinFormingofAdvancedHighStrengthSteels,J.Mater.Process.Technol.,2007,190,p189–198

[3]R.Kolleck,D.Steinhoefer,J.A.Feindt,etal.,ManufacturingMethodforSafetyandStructuralBodyPartsforLightweightBodyDesign,Proceedings,IDDRG,Sindelfingen,2004,p167–173

[4]'FiniteElementAnalysisforDesignEngineers',PMKurowski,SAEInternational,2004,ISBN:

0-7680-1140-X.

[5]'MechanicsandMaterialsforDesign',