Functional Analysis of Components Manufactured by a Sheet-Bulk Metal Forming Process

Hetzel, Andreas; Schulte, Robert; Vogel, Manfred; Lechner, Michael; Besserer, Hans-Bernward; Maier, Hans Jürgen; Sauer, Ch.; Schleich, Benjamin; Wartzack, Sandro; Merklein, Marion

doi:10.3390/jmmp5020049

Cited by 3 publications

(2 citation statements)

References 24 publications

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“…The paper [3] provided an innovative of sheet-bulk metal forming (SBMF) process. It found that the hardness distribution and homogeneity of the forming parts are improved.…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

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Implementation of finite element analysis for solving the constraints in forming process of large steel parts

Jawad

Jaber

Ibrihim

2022

EEJET

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In recent years, the demand for high-durability parts are rising too much. These challenges are difficult to overcome without an innovative framework based on an accurate database. The problems of high stress generated due to the hard friction and severe crystal dislocation during the forming process need to be solved. High frictional forces between the contact surfaces while forming lead to high sticking between the parts. In this work, forming process of the large sheet metal has been explored based on some parameters like material properties, stress generation, and their effects on the product quality. For this purpose, square sheet metal of 721*721*5 mm is considered, and the product formation through many forming steps was carried out. This work includes adopting some design steps, modeling, and analysis to control some parameters and minimize the generation stresses. The finite element software (ABAQUS/CAE) has been adopted for analyzing this process. In this simulation, the forming process evolution in different steps has been analyzed, and the influence of the effective parameters was performed. As a result, it’s found that the generation stresses are highly concentrated near the fillet zones and proportional to the pressure, and depend on the nature of contact and friction. Simulation results also revealed that the uniform pressure during forming will leads to minimizing the friction and stress generation (5 %) and this will improve the product quality. Also, it’s possible to identify and facilitate many difficulties and evaluate the possibilities before further investing in tooling. It’s concluded that any accurate process like this must depend on some sequence steps like design, modeling, and simulation. Moreover, folding the large surface area needs accurate and adjustable types of equipment.

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“…The paper [3] provided an innovative of sheet-bulk metal forming (SBMF) process. It found that the hardness distribution and homogeneity of the forming parts are improved.…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

“…For comparison purposes, the results obtained by [3] approved that the hardness homogeneity distribution can be improved and the process failures can be prevented in a forming process (Functional Analysis). These findings are matching with the results obtained here.…”

Section: Fig 19 Energy-time Relationshipmentioning

confidence: 99%

Implementation of finite element analysis for solving the constraints in forming process of large steel parts

Jawad

Jaber

Ibrihim

2022

EEJET

View full text Add to dashboard Cite

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Surface and subsurface material modifications and graded material properties in sheet steel 1.0338 (DC04) and their influence on forming processes

Zielinski,

Zettl,

Lafarge

et al. 2023

Prod. Eng. Res. Devel.

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For bulk material it is very well known, that the material properties differ between the material near the surface and the inner material (i.e. segregations). However, for sheet material a gradient of material properties in depth direction and its influence on forming processes was not yet investigated. Within experiments on sheet steel 1.0338 (DC04) a gradient in material properties was proven by hardness measurements for both unprocessed material as well as after conducting forming and milling processes. The characterisation shows a gradient in material hardness over the entire sheet thickness. The experimental results regarding forming processes, such as rolling and bending, additionally show an increase of the materials hardness due to work hardening. The problem from the inhomogeneous material properties leads to an inaccurate prediction of the forming behaviour of the workpiece in further processing. Machining experiments were conducted for transferring the knowledge of modified surface and subsurface layers onto forming processes and their simulation. The bending experiments and the corresponding process simulation of the spring back behaviour show, that the implementation of an inhomogeneous material property increases the prediction accuracy. Notably the prediction of the spring back behaviour of thinner sheet metals is highly improved. Therefore, an analysis of sheet metal properties in thickness direction and their consideration in forming process simulations is inevitable for the implementation of accurate material models.

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Impact of Uniaxial Pre-Strains on the Forming Limit Curve (FLC) of CuZn 70-30 Brass Sheets for Enhanced Formability in Production Applications Using the Nakajima Test

Abed,

Shwaish,

Abbas

et al. 2024

JMMP

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Brass sheets are extensively utilized in the automotive, electrical, and other industries, where an in-depth understanding of their formability is crucial for achieving optimal performance in production applications. This study investigates the influence of uniaxial pre-strains on the Forming Limit Curve (FLC) of CuZn 70-30 brass sheets, which aims to enhance their formability by identifying and optimizing key forming parameters. Adding a new variable, the impact of uniaxial pre-strain upon FLC, was our aim of this study and, consequently, the CuZn 70-30 brass sheet formability using punch-stretching tests with purpose-built tools, we experimentally obtained FLCs for brass sheets under varying levels of pre-strain (0.04, 0.06, and 0.08) applied through uniaxial tension by using Nakajima tests with purpose-built tools. The objective was to understand how specific factors such as punch parameters, punch corner radius, and strain rate impact the FLC and, consequently, the brass sheets formability. Results indicate a distinct trend of increasing pre-strain levels leading to a significant rise in minor strain capacity along the right portionof the FLC, with a comparatively insignificant effect on the left. This consistent elevation across strain paths suggests improved formability due to pre-straining, highlighting the potential for optimized manufacturing processes and enhanced product quality across industrial applications.

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Functional Analysis of Components Manufactured by a Sheet-Bulk Metal Forming Process

Cited by 3 publications

References 24 publications

Implementation of finite element analysis for solving the constraints in forming process of large steel parts

Implementation of finite element analysis for solving the constraints in forming process of large steel parts

Surface and subsurface material modifications and graded material properties in sheet steel 1.0338 (DC04) and their influence on forming processes

Impact of Uniaxial Pre-Strains on the Forming Limit Curve (FLC) of CuZn 70-30 Brass Sheets for Enhanced Formability in Production Applications Using the Nakajima Test

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