A Numerical and Experimental Study of Constrained Ironing Process as a Novel High Thickness Reduction Ironing Method

Khodsetan, M.; Faraji, Ghader; Abrinia, Karen; Karami, Javad Shahbazi

doi:10.1007/s12666-016-0843-6

Cited by 1 publication

(2 citation statements)

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“…The purpose of this study was to investigate the effect of TRR parameters, die angle, and coefficient of friction in the constrained ironing process. The results of the study using FEM showed that the effect of increasing TRR from 60 % to 80 % of the punch force showed an increase, increasing the die angle resulted in a decrease in the punch force, the greater the coefficient of friction between the die and the cup and the cup and punch, the larger the punch force required [2]. The subject of this research is about the effect of TRR, die angle, and coefficient of friction on the punch force.…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

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Determination of the effect of thickness reduction ratio, die angle, and coefficient of friction on residual stresses in ironing process: an analysis using computer simulation

Faizin¹,

Londen²,

Pramono³

et al. 2021

EEJET

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Ironing is a part of the group of metal forming processes, the process of reducing the thickness of the wall of a cup-shaped product. External load required to process metal forming, can cause residual stress. Residual stress can be beneficial or detrimental depending on the function of the product, the magnitude, and direction of the residual stress. Residual stress can act as an additional load on a given load. Residual stress can affect product quality, namely: dimensional accuracy, surface roughness, and mechanical properties. The speed of the ironing process is strongly influenced by the mechanical properties of the cup material, Thickness Reduction Ratio (TRR), and press tool design. The ironing process has a limited TRR value and if it is exceeded it results in product damage. Various studies on ironing were carried out to obtain an optimal process. In this research, stress analysis was carried out using the ANSYS software modeling simulation to obtain the occurring residual stress during the ironing process. The analysis was carried out by varying the TRR from 20 % to 30 %, the die angle from 25° to 30°, and the coefficient of friction from 0.05 to 0.15. Furthermore, processing and analysis of the stress analysis data are carried out to obtain the most dominant variables affecting the residual stress and the variable value that produces the lowest residual stress. Stress analysis was carried out on AA1100 aluminum cups with an outer diameter of 37 mm, a height of 20 mm, and a wall thickness of 2 mm. The results show that TRR and coefficient of friction are the most dominant variables affecting residual stress, while die angle has no significant effect. The lowest residual stress occurs at TRR 30 % and coefficient of friction 0.15

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Section: Literature Review and Problem Statementmentioning

confidence: 99%

“…At low TRR, in order to achieve the desired thickness, the process must be repeated several times. On the other hand, at high TRR, a large punch force is required, so there is a high risk of product damage [2].…”

Section: Introductionmentioning

confidence: 99%