Hydro-mechanical Deep Drawing (HMD) is an advanced manufacturing process developed to form sheet metal blanks into complex shapes with smooth surfaces using hydraulic pressure as an additional source of deformation force. There are many factors affecting the successful production of desired parts using this manufacturing process. The most important factors are the fluid pressure and blank holder force. Having proper values of these parameters during forming has a direct impact on part properties such as drawing ratio and thinning. In order to determine desired the fluid pressure and blank holder force profiles, which are different for every geometry, material and other process conditions, finite element simulations are conducted to save time and cost. Abaqus FEA software is used in this study. In order to define the continuously changing fluid pressure application area on the sheet material, which is not an available module or standard interface of software, sub-programs (sub-routines) are developed to properly and dynamically define the fluid pressure area. Proper, if not optimal, fluid pressure and blank holder force profiles, which allow the formability (LDR) of sheet material to be maximum, were obtained using trial and error method. Maximum thinning values on metal blank were used as a control parameter to determine if selected loading profiles result in the highest LDR with lowest thinning.
Hydromechanical deep drawing Determination of Hydromechanical deep drawing process parameters by means of the analogy method Production of industrial product In this study, in order to meet the demand for fast and economical production of sheet metal products, the design and manufacture of hydroforming dies have been carried out in order to reduce the number of operations in production of teapot, which is produced with many operations by conventional deep drawing. Integrated adaptive FEA and fuzzy logic control algorithm were used for determine die and process parameters. Prior to the manufacturing of large sized and therefore costly 1:1 scale die required for the production of industrial products, the validity of the die and process parameters determined by the laboratory press with low cost 1:4 scale dies in the Hydromechanical Deep Drawing (HDD) method was investigated using 1:1 scale dies by means of the analogy method. HDD was applied with 1:1 scale die using the die and process parameters obtained from 1:4 scale dies. The teapot, which can be formed in four stages with conventional drawing, could be successfully produced in only one stage with HDD. Figure A. Successfully formed teapot Purpose: The aim of this study is to design and manufacture hydroforming dies in the production of sheet metal products, in order to produce the teapot produced in many stages with less classic deep drawing in order to meet the demand for fast and economical production. Theory and Methods: HDD was applied with 1:1 scale die using the die and process parameters obtained from 1:4 scale dies by means of the analogy method. Results: HDD was applied with 1:1 scale die using the die and process parameters obtained from 1:4 scale dies. The teapot, which can be formed in four stages with conventional drawing, could be successfully produced in only one stage with HDD. Conclusion: Before the manufacturing of the 1:1 scale die required for the production of the industrial product, a significant contribution has been made by determination of sealing system and process parameters using 1:4 scale model dies in accordance with the simulation rules.
In this study, a hydroforming system was designed, built, and experimentally validated to perform lab-scale warm hydromechanical deep drawing (WHDD) tests and small-scale industrial production with all necessary heating, cooling, control and sealing systems. This manuscript describes the detailed design and fabrication stages of a warm hydroforming test and production system for the first time. In addition, performance of each subsystem is validated through repeated production and/or test runs as well as through part quality measurements. The sealing at high temperatures, the proper insulation and isolation of the press frame from the tooling and synchronized control had to be overcome. Furthermore, in the designed system, the flange area can be heated up to 400 °C using induction heaters in the die and blank holders (BH), whereas the punch can be cooled down to temperatures of around 10 °C. Validation and performance tests were performed to characterize the capacity and limits of the system. As a result of these tests, the fluid pressure, the blank holder force (BHF), the punch position and speed were fine-tuned independent of each other and the desired temperature distribution on the sheet metal was obtained by the heating and cooling systems. Thus, an expanded optimal process window was obtained to enable all or either of increased production/test speed, reduced energy usage and time. Consequently, this study is expected to provide other researchers and manufacturers with a set of design and process guidelines to develop similar systems.
No abstract
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.
hi@scite.ai
10624 S. Eastern Ave., Ste. A-614
Henderson, NV 89052, USA
Copyright © 2024 scite LLC. All rights reserved.
Made with 💙 for researchers
Part of the Research Solutions Family.