Simulation of channel forming based on ABAQUS.docx

1、Simulation of channel forming based on ABAQUSSimulation of channel forming based on ABAQUS1257747 Miao YuAbstractDuring the development of manufacturing processing, the main problem to the mold designer is longer design time, especially for some complex sheet metal forming parts. The invited and dev

2、elopment of sheet metal forming CAE technology and forming analysis software, effectively reduce the time of design, greatly reduce the test time, help designer to improve product quality, reduce production cost. Sheet metal forming is to use molds for sheet metal stamping processing, to form light

3、mass, smoothly surface, beautiful out looking product. It has advantages of saving material, high efficiency and low cost. It is widely used in such as automotive, aerospace, mold industry area. This article, use ABAQUS to simulate the channel forming, learn how CAE software can effectively reduce t

4、he time of design and analysis how radius, coefficient of friction between the blank and the die, blank holder force effect on stress distribution and punch force.Key word: CAE ABAQUS Channel formingIntroductionSheet metal forming process is to give a force on the sheet metal by mold, make the sheet

5、 metal to produce plastic permanent deformation, in order to obtain the desired product shape. In this process, there have many issues can affect the deformation of sheet metal and it is hard to control the deformation shape. 1First, when give the metal an external force, it will deformed, the defor

6、mation can be divided into the elastic deformation and plastic deformation, elastic deformation is reversible, when remove the external force after deformation, it will replaced to its original shape. Second, the composition and organization of metal has a great effect on deformation. Thirdly, the c

7、oefficient of friction also effect on deformation. So, it is very hard to analysis what will happened during deformation for industry until CAE technique had been invited. 1 2Computer aided engineering is based on engineering and science, set up model and simulate on a computer. On the one hand, the

8、 application of CAE technology, solve many complex problems that cannot be analysis in the past. On the other hand, it makes a lot of complex engineering analysis problems become simplified, save a lot of time, avoid the repeated work, let engineering analysis become faster and accurate and also sav

9、e huge of money from industry. It is very important during product design, product analysis and new product research and development. Now, with the development of CAE technology, it is already become an essential tool to the industry. ABAQUS is powerful engineering simulation software of the finite

10、element, it can not only analysis simple linear problems but also analysis many complex non-linear problems. ABAQUS, including a rich, can simulate arbitrary geometry cell library. And it has a material library that has various types of materials. As general purpose simulation software, it can analy

11、sis almost all kind of engineering problems. 2 3 4In this article, use ABAQUS to simulate the channel forming, learn how CAE software can effectively reduce the time of design and analysis how radius, coefficient of friction between the blank and the die, blank holder force effect on stress distribu

12、tion and punch force.Experimental and resultFirst, according to ABAQUS Example 4, when die radius equal to 0.005, the coefficient of friction between the blank and the die equal to 0.1 and the blank holder force equal to 440, the stress and strain distributions and punch force curve shows below:Forc

13、e curveStrain distributionStress distributionSecond, change the die radius to 0.003, then the result shows below:Force curveStrain distributionStress distributionThird, change the die radius to 0.007, then the result shows below:Force curveStrain distributionStress distributionFourth, keep die radiu

14、s equal to 0.005, change coefficient of friction to 0.05, the result shows below:Force curveStrain distributionStress distributionFifth, change coefficient of friction to 0.015, the results shows below:Force curveStrain distributionStress distributionSixth, change coefficient of friction to 0.2, the

15、 results shows below:Force curveStrain distributionStress distributionSeventh, keep die radius equal to 0.005, coefficient of friction equal to 0.1, change blank holder force to 420, the result shows below:Force curveStrain distributionStress distributionEighth, change blank holder force to 460, the

16、 results shows below:Force curveStrain distributionStress distributionNinth, change blank holder force to 480, the result shows below:Force curveStrain distributionStress distributionDiscussion1. Die radius effects forming process.1.1 Die radius effects stress distribution.Stress distribution(r=0.00

17、3)Stress distribution(r=0.005)Stress distribution(r=0.007)Picture above shows the stress distribution according to different die radius. In the right part of blank, when die radiuses become larger, the stress becomes larger. In the left part of blank, when die radius increased, the stress becomes sm

18、aller. From picture above, the stress is very small on left or right part of blank. The part of blank related to die radius has the largest different when change radius. When die radius become larger, the part of blank related to die radius will become very weak, during the usage of this work piece,

19、 this will broke first.1.2 Die radius effect punch force.Force curve(r=0.003)Force curve(r=0.005)Force curve(r=0.007)Picture above shows the force curve according to different die radius. From these pictures, when r=0.003, the maximum force=0.185*1e6, when r=0.005, the maximum force=0.18*1e6, when r

20、=0.007, the maximum force=0.175*1e6. So, when die radiuses become larger, the force will become smaller.2. Coefficient of friction effect forming process.2.1 Coefficient of friction effect stress distribution.Stress distribution (coefficient=0.015)Stress distribution (coefficient=0.05)Stress distrib

21、ution (coefficient=0.1)Stress distribution (coefficient=0.2)Picture above shows stress distribution according to different coefficient. In the right part of blank, when coefficient becomes larger, the stress reduced first, then increased. When coefficient equal to 0.1, it has the smallest stress.In

22、the left part of blank, when coefficient increased, the stress slightly increased, when coefficient equal to 0.2, it has the largest stress. The stress distribution on part of blank face to die radius has been increased when coefficient increased. The stress distribution on part of blank face to pun

23、ch increased first, then becomes smaller, then increased again.2.2 Coefficient of friction effect punch force curveForce curve (coefficient=0.015)Force curve (coefficient=0.05)Force curve (coefficient=0.1)Force curve (coefficient=0.2)Figure above shows force curve according to different coefficient.

24、 The maximum force is when coefficient=0.2, force=0.29*1e6. So when coefficient increased, force increased.3. Blank holder force effect forming process.3.1 Blank holder force effect stress distribution.Stress distribution (f=420)Stress distribution (f=440)Stress distribution (f=460)Stress distributi

25、on (f=480)Figures above shows stress distribution according to different blank holder force. In these figures, it clear shows that when blank holder force increased, the stress distribution on the right part of blank decreased first, then increased. The stress distribution on the other part does not

26、 change. This means that the blank holder force cannot effect stress distribution.2.2 Blank holder force effect punch force curve.Force curve (f=420)Force curve (f=440)Force curve (f=460)Force curve (f=480)Figures above shows force curve according to different blank holder force. When f=420, the max

27、imum force=0.165*1e6. When f=440, the maximum force=0.175*1e6. When f=460, the maximum force=0.185*1e6. When f=480, the maximum force=0.19*1e6. So, when blank holder force increased, the punch force increased.ConclusionSheet metal forming process is to give a force on the sheet metal by mold, make t

28、he sheet metal to produce plastic permanent deformation, in order to obtain the desired product shape. During the development of manufacturing processing, the main problem to the mold designer is longer design time, especially for some complex sheet metal forming parts. The invited and development o

29、f sheet metal forming CAE technology and forming analysis software, effectively reduce the time of design, greatly reduce the test time, help designer to improve product quality, reduce production cost. In this article, use ABAQUS to simulate the channel forming, learn how CAE software can effective

30、ly reduce the time of design and analysis how radius, coefficient of friction between the blank and the die, blank holder force effect on stress distribution and punch force. The result shows that die radius, coefficient of friction between the blank and the die, the blank holder force have a great

31、effect on this forming process.References1 M. Kleiner, M. Geiger, and A. Klaus, Manufacturing of Lightweight Components by Metal Forming, Ann. CIRP, 2003, 52(2), p 5215422 P. Chen and M. Koc, Simulation of Springback Variation in Forming of Advanced High Strength Steels, J. Mater. Process. Technol.,

32、 2007, 190, p 189198 3 R. Kolleck, D. Steinhoefer, J.A. Feindt, et al., Manufacturing Method for Safety and Structural Body Parts for Lightweight Body Design, Proceedings, IDDRG, Sindelfingen, 2004, p 167173 4 Finite Element Analysis for Design Engineers, P M Kurowski, SAE International, 2004, ISBN: 0-7680-1140-X.5 Mechanics and Materials for Design,