Velocity effects in metal forming and machining processes

Neugebauer, Reimund; Bouzakis, K.‐D.; Denkena, Berend; Klocke, Fritz; Sterzing, Andreas; Tekkaya, A. Erman; Wertheim, R.

doi:10.1016/j.cirp.2011.05.001

Cited by 130 publications

(63 citation statements)

References 83 publications

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“…High speed processes can lead to economical and technological benefits [1]. As described in [2] high speed effects enable the manufacturing of products with higher quality and without any additional finishing in contrast to conventional processes as confirmed in the investigations of Jana and Ong in [3].…”

Section: Introductionmentioning

confidence: 75%

“…As described in [2] high speed effects enable the manufacturing of products with higher quality and without any additional finishing in contrast to conventional processes as confirmed in the investigations of Jana and Ong in [3]. Furthermore, forming at high velocity enables improved material utilisation, reduction of needed process forces and allows to form materials that are not formable with conventional processes as described in [1]. High strain rates of 500 s -1 and higher can result in scaling up the flow stresses compared to quasistatic forming or cutting of strain rate depending materials.…”

Section: Introductionmentioning

confidence: 77%

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Characterisation of high strain rate material behaviour for high-speed forming and cutting applications

Tulke

Scheffler

Linnemann

et al. 2018

J. Phys.: Conf. Ser.

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Abstract. Determination of the material behaviour for high speed forming processes is challenging due to high process velocity and small specimen geometry in experimental analysis. This paper proposes two different material characterisation concepts for high strain rates at 10³ s -1 and higher, namely a pneumatically device and an electromagnetically accelerated hammer, for obtaining experimental values. Furthermore, two measuring principles of the hammer velocity and displacement are presented and compared. The authors describe a measurement system with an acceleration sensor for the pneumatic device and a shadowing principle for the electromagnetically driven concept. Using the measured data, material parameters are iteratively adapted in an optimisation procedure until an objective function, comparing the difference between numerical and experimental results, is satisfied. In this case the parameter identification is applied on a strain rate dependant flow curve approximation based on Johnson-Cook.

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Section: Introductionmentioning

confidence: 75%

Section: Introductionmentioning

confidence: 77%

Characterisation of high strain rate material behaviour for high-speed forming and cutting applications

Tulke

Scheffler

Linnemann

et al. 2018

J. Phys.: Conf. Ser.

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“…Helu, et al (2012) estudia el impacto de las estrategias de mecanizado "verdes" en la calidad alcanzada de las superficies generadas. Neugebauer et al (2011) estudia los efectos de la velocidad en el conformado de metales y los procesos de mecanizado. Safaieh et al (2013) analiza el problema de la no interoperabilidad entre diferentes tecnologías CNC, causada por la falta de estandarización para representar la geometría de las partes y la semántica de las operaciones de mecanizado, que conllevan a la necesidad de realizar un programa único para cada máquina diferente.…”

Section: Introductionunclassified

Estrategia de Mecanizado Aplicada a un Pequeño Torno Convencional Adaptado a CNC

et al. 2014

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ResumenEn este artículo se presenta la estrategia de mecanizado implementada en un sistema modular desarrollado para permitir la conversión de tornos convencionales a tornos CNC de forma sencilla y asequible para la pequeña y mediana industria local. En el desarrollo del artículo, se expone, en términos generales, las características del sistema, y se enfatiza en aspectos adicionales del sistema mecánico y de software. Igualmente, se describe detalladamente la estrategia de mecanizado implementada, la cual facilita la fabricación de piezas de revolución a partir de un perfil 2D realizado en cualquier programa de diseño asistido por computador. No se hace uso de códigos G. Finalmente, se dan los resultados obtenidos en la fabricación de algunas piezas de ajedrez (una torre y un alfil), y se comparan con los resultados obtenidos en versiones anteriores del sistema, demostrando su mejor desempeño. Palabras clave: torno convencional, torno CNC, mecanizado, piezas de revolución, CAD Machining Strategy Applied to a Small Conventional Lathe adapted to CNC AbstractThis paper presents the machining strategy implemented in a modular system developed for the conversion of conventional lathes to a numerical control machine. The objective is to make the system simple to install and cheap enough to make it affordable to the local small and medium-sized Enterprise. General characteristics of the developed system are exposed. This work emphasizes in the mechanical and software systems. The machining strategy, implemented in the software, is deeply studied. This strategy makes it easy to manufacture solids of revolution, just with a previous 2D design made in any computer-aided design software. No G code is used. Finally, other chess pieces (a rook and a bishop) are manufactured, and obtained results are compared with those obtained in the previous version of the system. The better performance is verified.

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“…In the sheet forming with a die, it is very important to obtain the distribution of sheet velocity for the sake of controlling the deformation of the sheet [30], especially for the high-speed forming process, e.g., electromagnetic forming. By considering that the largest velocity of the grid-rib panel appears in the discharging forming stage for each pass, the Z-velocity distributions of aforementioned four panels during the first discharging forming stage in the EMIF process are studied with the velocity variation characteristics being concerned, which is shown in Figure 18.…”

Section: Velocity Distributionmentioning

confidence: 99%

Guideline for Forming Stiffened Panels by Using the Electromagnetic Forces

Tan

Zhan

Liu

2016

Metals

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Electromagnetic forming (EMF), as a high-speed forming technology by applying the electromagnetic forces to manufacture sheet or tube metal parts, has many potential advantages, such as contact-free and resistance to buckling and springback. In this study, EMF is applied to form several panels with stiffened ribs. The distributions and variations of the electromagnetic force, the velocity and the forming height during the EMF process of the bi-directional panel with gird ribs are obtained by numerical simulations, and are analyzed via the comparison to those with the flat panel (non-stiffened) and two uni-directional panels (only with X-direction or Y-direction ribs). It is found that the electromagnetic body force loads simultaneously in the ribs and the webs, and the deformation of the panels is mainly driven by the force in the ribs. The distribution of force in the grid-rib panel can be found as the superposition of the two uni-directional stiffened panels. The velocity distribution for the grid-rib panel is primarily affected by the X-directional ribs, then the Y-directional ribs, and the variation of the velocity are influenced by the force distribution primarily and secondly the inertial effect. Mutual influence of deformation exists between the region undergoing deformation and the deformed or underformed free ends. It is useful to improve forming uniformity via a second discharge at the same position. Comparison between EMF and the brake forming with a stiffened panel shows that the former has more advantages in reducing the defects of springback and buckling.

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Velocity effects in metal forming and machining processes

Cited by 130 publications

References 83 publications

Characterisation of high strain rate material behaviour for high-speed forming and cutting applications

Characterisation of high strain rate material behaviour for high-speed forming and cutting applications

Estrategia de Mecanizado Aplicada a un Pequeño Torno Convencional Adaptado a CNC

Guideline for Forming Stiffened Panels by Using the Electromagnetic Forces

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