Comparison of the numerical and experimental results of the sheet metal flange forming based on shell-elements types

Vafaeesefat, Abbas; Khanahmadlu, Morteza

doi:10.1007/s12541-011-0114-8

Cited by 13 publications

(6 citation statements)

References 12 publications

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“…FE simulation results in terms of punch load, thickness variation, and finished shape were compared with experimental results. Vafaeesefat and Khanahmadlu [14] investigated forming of two types of Z-flange, one performed on a circular blank with an inner hole and another one was a simple stretch forming by a single punch to expand a cut-out blank. Riadh Bahloul [15] optimized the process parameters and minimization of stresses and Lemaitre damage in flanging process using numerical simulation and ductile damage model of Lemaitre.…”

Section: Introductionmentioning

confidence: 99%

“…Steel, copper and aluminium specimen were used to perform the tensile test experiments and to compare the FEM results in terms ductile fracture strain at various fracture location. It can be summarise from the literature review that in stretch flanging process [14,[37][38][39] deformation behaviour of sheet and fracture in sheet have been widely investigated considering various parameters such as material parameters [1,17,23], geometrical parameters [1,4,11,13,16,23,26,31,37,40,41], blank holding force [7,31], friction coefficient [7,23,26,31,42]. Different punch shape has also been used in other sheet metal forming processes such as stretch, shrink, hole flanging and deep drawing process [2, 27-29, 33, 35, 36, 41].…”

Section: Introductionmentioning

confidence: 99%

“…Different punch shape has also been used in other sheet metal forming processes such as stretch, shrink, hole flanging and deep drawing process [2, 27-29, 33, 35, 36, 41]. FEA is an easy and efficient way to apply various ductile failure criterions [18,[43][44][45][46][47][48] and to determine the failure in stretch flanging process [14,[37][38][39] considering various parameters.…”

Section: Introductionmentioning

confidence: 99%

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Effect of punch profile on deformation behaviour of AA5052 sheet in stretch flanging process

Kumar

Ahmed

Panthi

2020

Archiv.Civ.Mech.Eng

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Stretch flanging is a type of bending process widely used in automobile and aerospace industries. Forming of the stretch flange is mainly affected by three important parameters: materials of the sheet, the geometry of tools and different process parameters. This work focuses on the effect of punch profile on deformation behavior of AA5052 alloy sheet to form the stretch flange. Six punches of different geometry i.e. cylindrical, two stepped, three stepped, six stepped, conical and hemispherical are used. Results are presented in the form of edge crack in the sheet at edge corner and its propagation towards center, forming load comparison for different punch profile and distribution of radial and circumferential strain in the sheet. It is observed that the punch profile has a considerable effect on the deformation behavior of the sheet. Circumferential strain, radial strain and load requirement to form the flange are found to be minimum in hemispherical punch profile as compared to other punch profiles. Experiments are performed to validate the FE simulation results and results are found in very good agreement in terms of edge crack length. Fractography study shows uniform and large number of small size dimples at the fractured surface for hemispherical and conical punch profile.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Effect of punch profile on deformation behaviour of AA5052 sheet in stretch flanging process

Kumar

Ahmed

Panthi

2020

Archiv.Civ.Mech.Eng

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“…Sartkulvanich et al [24] developed the FEM model for the characterization of blank edge quality for different punch/die clearance of advanced high-strength steel (AHSS) in stretch flanging process. Vafaeesefat Abbas and Khanahmadlu Morteza [25] compared the FEM simulation with experimental results in terms of shell-element in stretch z-flange-forming process. Golovashchenko [26] improved the quality of trimming process in stretch flanging of aluminum alloys AA6111-T4 sheet.…”

Section: Introductionmentioning

confidence: 99%

Investigation on the Crack and Thinning Behavior of Aluminum Alloy 5052 Sheet in Stretch Flanging Process

Kumar

Ahmed

Panthi

2020

J Fail. Anal. and Preven.

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Stretch flanging is the important sheet metalforming process which is widely used in automobile and aerospace sectors. The formability of sheet metal depends on various parameters such as material properties, geometry of the tool setup and process parameters. In the present work, effects of different die radius and sheet width on deformation behavior of sheet are studied by FEM simulation and experiments. The predicted FEM results are presented in the form of edge crack location and its propagation, crack length, forming load and strain distribution in sheet along the die profile radius. This study indicates that crack length increases with increase in the sheet width, while the crack length decreases with increase in the die radius. It is found that the crack propagation in stretch flanging process is affected by the strain distribution in sheet and this distribution of strain depends on many parameters. The crack initiates during deformation of the sheet at the die corner edge and propagates toward the center of the sheet along the die profile radius. Simulation results are compared with the experimental one in terms of crack length and variation in sheet thickness. FE simulation results are found in very good agreement with experimental results. Fractography study is also presented in terms of size, shape of the dimples along with their distribution on the fractured surface. Keywords Stretch flanging process Á Finite element simulation Á Edge crack Á Crack length Á Forming load Á Strain and thickness distribution Á Fractography

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“…The flanging process is always studied by regarding the plate as a sheet, thus the research can focus on the neutral surface and ignore the thickness. The shell element adopted in FE modeling can describe the deformation characteristic during hole flanging with thin sheets [19]. However, this method is not proper for the thick plate, especially the thick cylinder, since the shape is influenced by the deformation along the thickness direction.…”

Section: Introductionmentioning

confidence: 99%

Through-Process Finite Element Modeling for Warm Flanging Process of Large-Diameter Aluminum Alloy Shell of Gas Insulated (Metal-Enclosed) Switchgear

2019

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The large diameter metal shell component (LDMSC) is an important part of gas insulated (metal-enclosed) switchgear (GIS). The LDMSC with multi branches is filled with gas under certain pressure. The plastic forming process is an efficient approach to manufacturing the high reliability LDMSC. The warm flanging process has been widely used to form LDMSC using aluminum alloy. The forming process is characterized by local heating, and the distribution of temperature is strongly inhomogeneous. Although the wall thickness of the shell is 10 mm to 20 mm, the ratio of outer diameter to thickness is more than 40. These present some difficulties in the flanging process and result in some forming defects. Detailed forming characteristics are hard to obtain by analytical and experimental methods. Thus, the through-process finite element (FE) modeling considering heating, forming, unloading, and cooling is one of the key problems to research the manufacturing process of LDMSC. In this study, the through-process FE modeling of the warm flanging process of LDMSC using aluminum alloy was carried out based on the FORGE. The thermo-mechanical coupled finite element method was adopted in the modeling, and the deformation of the workpiece and the die stress were considered together in the modeling. A full three-dimensional (3D) geometry was modeled due to inhomogeneous distribution in all directions for the temperature field. The simulation data of local flame heating could be transferred seamlessly to the simulations of the deforming process, the unloading process, and the cooling process in the through-process FE model. The model was validated by comparison with geometric shapes and forming defects obtained from the experiment. The developed FE model could describe the inhomogeneous temperature field along circumferential, radial, and axial directions for the formed branch as well as the deformation characteristic and the unloading behavior during the warm flanging process. By using the FE model, the forming defects during the flanging process and their controlling characteristics were explored, the evolution of the temperature field through the whole process was studied, and deformation and springback characteristics were analyzed. The results of this study provide a basis for investigating deformation mechanisms, optimizing processes, and determining parameters in the warm flanging process of a large-diameter aluminum alloy shell component.

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Comparison of the numerical and experimental results of the sheet metal flange forming based on shell-elements types

Cited by 13 publications

References 12 publications

Effect of punch profile on deformation behaviour of AA5052 sheet in stretch flanging process

Effect of punch profile on deformation behaviour of AA5052 sheet in stretch flanging process

Investigation on the Crack and Thinning Behavior of Aluminum Alloy 5052 Sheet in Stretch Flanging Process

Through-Process Finite Element Modeling for Warm Flanging Process of Large-Diameter Aluminum Alloy Shell of Gas Insulated (Metal-Enclosed) Switchgear

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