FEM and Experimental Based Analysis of the Stamping Process of Aluminum Alloy

In solving technological problems related to sheet metal deep drawing with the use of computer tools, the key issue is still the correct determination and entering of boundary conditions to FEM-based software. The procedure for preparing input data for modelling such processes includes geometric data (drawing of tools and material), technological parameters along with the contact conditions between the workpiece and the tools (friction model and type of lubricant) and material properties, in which work-hardening curves are of particular importance. In typical material databases of FEM-based software and designed for computer modelling of deep drawing processes, the properties of only a small number of material grades are available, and commercial software producers charge additional fees for each additional quantity. Those properties that are already in the database are usually devoid of basic information, e.g. related to the state of the material (material after recrystallization, annealing, cold working has different properties). In paper, experimental tests were carried out to determine flow curves based on cold tensile curves for flat samples made of EN-AW 1050A aluminium, Cu-ETP copper, CuZn37 brass and S235JRG2 steel. The investigation used a universal testing machine with a 20 kN pressing force, equipped with specialized Test&Motion software for measuring forces and displacements. It was calibrated and satisfies the metrological requirements for class 0.5. A comparative analysis of the curves determined by the analytical method was carried out. The material models obtained in the experimental tests were used in the computer simulation of the deep drawing processes of cylindrical drawpieces in the ABAQUS software. The results were experimentally verified in terms of comparing the changes in the pressing forces as a function of the displacement of the punch. The results obtained in the research can be used in industrial practice for computer-aided design of cold-deep drawing processes for drawpieces of various shapes from the discussed materials.

Section: Results and Analysissupporting

confidence: 80%

Section: Results and Analysismentioning

confidence: 87%

Section: Results and Analysismentioning

confidence: 90%

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Experimental Determination of Material Boundary Conditions for Computer Simulation of Sheet Metal Deep Drawing Processes

Miłek

2023

“…The simulations were made in Deform-3D. This software has been effectively used in previous studies to investigate metal forming processes [9][10][11]. The simulations were performed on material models of aluminium alloys obtained from the software's material database.…”

Section: Methodsmentioning

confidence: 99%

Investigation of the Deformability of Aluminium-Copper Casting Alloys

Winiarski¹,

Dziubińska²,

Majerski³

et al. 2018

The paper presents the results of a numerical analysis and experimental tests investigating the deformability of castings made of two aluminium alloys: EN AW-2017A and EN AW-2024. Test specimens were produced by two casting methods: sand casting and permanent mould casting. The castings were first subjected to homogenizing annealing; afterwards, they were shaped into cylindrical specimens for an upsetting test. This test was conducted on a hydraulic press in the temperature range of 420-500˚C. Visual inspection of the specimens and examination of their microstructure were performed. Hardness of selected specimens was also measured. The study led to determination of the effect of the mould type on the deformability of the castings and the hardness of forgings obtained from these casting. Obtained results also became a basis for determining the forging temperature ranges for casting preforms made of the investigated aluminium alloys.

“…FEA simulation is a popular numerical method for solving structural, vibration, and heat problems by predicting design responses [26,27]. Due to the need to simulate the static strength of the chosen material, steps of the plan interaction were applied, beginning with drawing the threedimensional model of the collapsible pot hauler with computer-aided design (CAD) programming [21,28,29]. Then, the simulation FEA process starts by demonstrating calculations that address the genuine models.…”

Section: Finite Element Analysis (Fea) Of the Selected Materialsmentioning

confidence: 99%

Material Selection of Collapsible Pot Hauler and Finite Element Analysis Simulation Applied to the Selected Material

Saputra¹,

Iskandar²,

Kurniawati³

et al. 2023

The current collapsible pot hauler uses a wooden frame, thus making much space in the working area of the fishing boat and also at this time challenging to find the best quality wood. In this study, the wood material would replace by metal; the selection of the proper material is critically needed. A suitable material means the applied material has to deal with environmental conditions. Finding the appropriate material applied to the collapsible pot hauler; can be determined using a Multi-Criteria Decision Making (MCDM) approach. After selecting the proper material, the collapsible pot hauler simulates the material stress using the Finite Element Analysis (FEA) simulation. The material for the new model of collapsible pot hauler was selected using the WSM method. The material with the highest rank (selected) is AISI 304, with a preference value of 3.58. The static strength simulation using the FEA method utilizing Solidworks Software shows that the yield strength value is still below the material properties, which a maximum value is 200 MPa, the material safety factor is the minimum value above one, which is 1.24 on the line spool plate shafts. It means that the material AISI 304 is safe to be applied to the collapsible pot hauler.