As the study of formability of perforated sheet metals using conventional approach is exhaustive and time consuming, Finite Element Analysis is used to carry out the same. This paper attempts to study the effects of perforation parameters (viz. hole size, open area and thickness) on the formability of square hole Perforated Mild Steel Sheet Metal. Finite element analysis is done using commercial Finite Element Analysis software LS-DYNA. Parametric analysis is carried out to optimize process parameters using Taguchi’s L9 orthogonal array. From the results obtained through simulation, the analysis of variance (ANOVA) is carried out to determine which group has best condition for drawing and regression equation is obtained to know, how a single response variable (Major or Minor strain) is related to a variety of predictor variables (percentage open area, hole size and thickness) and the graphs are plotted between them using MINITAB software.
Forming Limit Diagram (FLD) is a resourceful tool to study the formability of sheet metals. Research on the formability of Perforated Sheet Metal is growing over the years as perforated sheet metal finds its applications in various fields. But finding FLD of perforated sheet metals is complex due to the presence of holes. Also, the hole size, shape and pattern, ligament ratio, thickness of the blank, percentage of open area influence the formability of a perforated sheet metal.In the present scenario, various simulation softwares have made the process of plotting FLD much easier, saving time and money. This paper is an attempt to predict the formability of mild steel perforated sheet metal through simulation software package LS Dyna. Also, Parametric analysis is performed to determine the influence of geometric parameters on the drawability of the perforated sheet metal.
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