Modelling and Simulation of Sheet Metal Forming Processes

Oliveira, M. C.; Fernandes, J.V.

doi:10.3390/met9121356

Cited by 10 publications

(4 citation statements)

References 19 publications

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“…CP has been used to predict microstructure evolution during material deformation [ 28 , 29 , 30 , 31 ] as depicted in Figure 5 . Besides, the conventional numerical approach based on plasticity theory was coupled with damage models for predicting the flow behavior of metallic materials [ 32 ] and their forming limits [ 33 , 34 ] under complex forming conditions.…”

Section: Introductionmentioning

confidence: 99%

A Review of Characterization and Modelling Approaches for Sheet Metal Forming of Lightweight Metallic Materials

Hou

Myung

Park³

et al. 2023

Materials

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Lightweight sheet metals are attractive for aerospace and automotive applications due to their exceptional properties, such as low density and high strength. Sheet metal forming (SMF) is a key technology to manufacturing lightweight thin-walled complex-shaped components. With the development of SMF, numerical simulation and theoretical modelling are promoted to enhance the performance of new SMF technologies. Thus, it is extraordinarily valuable to present a comprehensive review of historical development in SMF followed by state-of-the-art advanced characterization and modelling approaches for lightweight metallic materials. First, the importance of lightweight materials and their relationship with SMF followed by the historical development of SMF are reviewed. Then, the progress of advanced finite element technologies for simulating metal forming with lightweight alloys is covered. The constitutive modelling of lightweight alloys with an explanation of state-of-the-art advanced characterization to identify the constitutive parameters are presented. Then, the formability of sheet metals with major influencing factors, the techniques for measuring surface strains in SMF and the experimental and modelling approaches for determining the formability limits are clarified. Finally, the review is concluded by affording discussion of the present and future trends which may be used in SMF for lightweight metallic materials.

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Section: Introductionmentioning

confidence: 99%

A Review of Characterization and Modelling Approaches for Sheet Metal Forming of Lightweight Metallic Materials

Hou

Myung

Park³

et al. 2023

Materials

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“…However, it is difficult to manufacture truss core panels with high quality and lowcost owing to their complex three-dimensional shape. Because of the characteristics of thin-walled panels made of thin steel plates, it seems appropriate to use the sheet metal press method to fabricate truss core panels; however, the convex part of the truss core panel must be formed as high as possible using the deep-drawing method to increase the bending rigidity [27,28]. However, by forming the truss core as much as possible, the problem of extreme thinning of the plate can be observed locally.…”

Section: Introductionmentioning

confidence: 99%

Intermediate Model Design in the Progressive Stamping Process of a Truss Core Lightweight Panel

Tian

Kong²,

Zhao³

et al. 2022

Applied Sciences

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The truss core panel has been verified to be effective for structural weight reduction in former research studies. However, it is difficult to manufacture using the sheet metal pressing method because the forming height of the truss core panel is limited by the physical properties of the material. Although progressive stamping has been used to solve this problem, it is still difficult to practically use the truss core panel. In this study, the author proposed a manufacturing method and a hexagonal frustum intermediate structure to improve the forming quality of truss core panels using a progressive stamping method and verified its effectiveness through numerical analysis and prototype experiments. Compared to the conventional hemispherical intermediate model, the manufacturing process of the truss core panel using the proposed method was significantly improved.

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“…The methods used to represent the friction conditions in conventional SMF have been summarized by Trzepiecinski and Lemu [9], where the main advantages and disadvantages of the modeling methods of the friction phenomena in specific areas of the material are also presented. Experimental prediction of the frictional resistances is a key issue in the suitable setting of the numerical models of sheet metal forming process [10][11][12].…”

Section: Introductionmentioning

confidence: 99%

Effect of Lubrication on Friction in Bending under Tension Test-Experimental and Numerical Approach

Trzepieciński

Lemu

2020

Metals

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This paper is aimed to determine the value of coefficient of friction (COF) at the rounded edge of the die in the sheet metal forming operations using the bending under tension (BUT) test. The experimental part of the investigations is devoted to the study of the frictional resistances of low alloy steel sheet under different strains of the specimen, surface roughnesses of the tool and for different lubrication conditions. Three oils are destined for different conditions of duties in the stamping process. Numerical modeling of the material flow in the BUT test has been conducted in the MSC.Marc program. One of the objectives of the numerical computations is to know the type of the contact pressure acting on the cylindrical surface countersample in the BUT test by assuming the anisotropic properties of the metallic sheet. It has been found that the COF in the rounded edge of the die does not vary with increasing sheet elongation. Taking into account that normal pressure increases with increasing specimen elongation and workpiece material is subjected to strain hardening phenomenon, the COF value is very stable during the friction test. The effectiveness of the lubrication depends on the balance between two mechanisms accompanied by friction process: roughening of workpiece asperities and adhesion of the contacting surfaces. In the case of high surface roughness of tool due to a dominant share of ploughing, all of the lubricants used were not able to decrease the COF in a sufficient extent. The used lubricants were able to reduce the value of friction coefficient approximately by 3–52% in relation to the surface roughness of rolls.

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Modelling and Simulation of Sheet Metal Forming Processes

Abstract: Numerical simulation of sheet metal forming processes has become an indispensable tool for the design of components and their forming process, in industries ranging from the automotive, to the aeronautics, packing and household appliances [...]

Cited by 10 publications

References 19 publications

A Review of Characterization and Modelling Approaches for Sheet Metal Forming of Lightweight Metallic Materials

A Review of Characterization and Modelling Approaches for Sheet Metal Forming of Lightweight Metallic Materials

Intermediate Model Design in the Progressive Stamping Process of a Truss Core Lightweight Panel

Effect of Lubrication on Friction in Bending under Tension Test-Experimental and Numerical Approach

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