In aeronautic sectors, lightweight materials are very demanded in order to reduce fuel consumption. Therefore, thinning drawn cups are very recommended. Reduction of thickness led to many geometrical and physical failures that damage the final product. Since most lightweight materials had a high level of anisotropic, the presence of earrings is one of the most significant failures faced in the deep drawing process. Many functions were developed in order to control these undesirable earrings in sheet metal parts. In this paper, a simulation of a 3D cylindrical deep drawing model for AA1050 and AA1100 aluminum alloys using ABAQUS finite element software was achieved. Prediction of earing phenomenon in deep drawing process was carried out. Moreover, the impact of punch corner radius and die shoulder radius on flange earrings was analyzed and a reduction of the percentage of earring heights was investigated.
To ensure the safety and of reducing the costs of maintenances in railways systems, it is necessary to evaluate the life prediction of fatigue crack initiation in rolling contact fatigue starting from the defects. The influence of defects on the rolling contact fatigue was studied, we simulated two types of geometry of defect (circular and elliptic) and also we studied the influence of defects clusters. The stresses and deformations were analyzed in the vicinity of the defect. Calculations were carried out with four levels of loading with the code of finite elements ABAQUS-standard (version 6.3). The fatigue impact was evaluated by using the multiaxial fatigue parameter to estimate the rolling contact fatigue life.
To produce different cups from sheet metal, deep drawing is a vital process demanded by different industries such as automobile, aeronautics and so on. The comprehension of the process’s mechanics led to the correct determination of the factors which affect the deep drawing results. Experimental tests and numerical simulations are two significant ways for analysing the deep drawing process. Experimental tests are beneficial in studying the process to control the defect of the final product. However, to gain time and substantially reduce costs the numerical modelling became a common method which could be investigate the deep drawing technique through all steps of deformation. The Coulomb friction in contact regions is one of the most influencing parameters during deep drawing. This research emphasizes the influence of friction coefficient on deep drawing in three different regions: between blank surface and punch, blank surface and die, and blank surface and blank holder. For this purpose, a 3D Finite Element Model of AA2090 Al-Li alloy was carried out to simulate the process using ABAQUS software with A combination of the statistical approach based on Taguchi Techniques in order to predict the impact of friction coefficient Thickness variation have been studied, and the thinning region have been analysing for a cylindrical deep drawing process the results obtained were used as imputes of Taguchi method and the most appropriate combination of the Coulomb friction in the three regions concerning AA2090 Al-Li alloy was found.
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