A review on the evaluation of formability in sheet metal forming

Wankhede, Pankaj; Suresh, Kurra

doi:10.1080/2374068x.2020.1731229

Cited by 16 publications

(11 citation statements)

References 72 publications

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“…The graph obtained after plotting minor strain on the abscissa and major strain on the ordinate for the different strain paths shows a 'V' shape nature known as FLD. 7 Generally, the major and minor axes of the deformed grids are measured using mylar tapes, rulers, traveling microscopes, and stereomicroscopes. But, these methods are prone to error due to human interference and consume more time for measurements.…”

Section: Introductionmentioning

confidence: 99%

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A comparative study on the effect of grid printing methods and camera hardware in automatic strain measurement through CGA

Wankhede

Mahesh

Suresh

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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Strain analysis is an important step in sheet metal forming operations to identify the potential locations of failure. Circle grid analysis is a widely used method to evaluate the strains in sheet metal forming, where deformed circles on a formed component are measured to evaluate the strains at different locations. In this paper, two different USB cameras are used to capture the images of the deformed grids. The images are processed using the in-house software developed in MATLAB for strain measurement. The effect of image acquisition hardware and grid printing methods on strain measurement accuracy has been analyzed. For this, the sheets are printed with circular grids by screen printing, laser engraving, and electrochemical etching. The sheets are then deformed in incremental forming to produce different levels of strain in the formed components. The deformed grids on the formed components are captured using proposed USB cameras with appropriate attachments and processed by in-house strain measurement software. The strain measured using proposed hardware and software is also compared with the commercial strain measurement system. The mean absolute percentage error in strain measurement with the proposed USB cameras was found to be 0.671 and 0.761. The statistical results show that there is no evidence to support the hypothesis that the two hardware perform differently on average. Hence, the proposed hardware and software can be used in industry and research laboratories for strain analysis in sheet metal forming operations.

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Section: Introductionmentioning

confidence: 99%

“…The graph obtained after plotting minor strain on the abscissa and major strain on the ordinate for the different strain paths shows a ‘V’ shape nature known as FLD. 7…”

Section: Introductionmentioning

confidence: 99%

A comparative study on the effect of grid printing methods and camera hardware in automatic strain measurement through CGA

Wankhede

Mahesh

Suresh

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…Consequently, novel polar effective plastic strain (PEPS) forming limit diagrams were suggested as a solution for improving the accuracy of formability predictions. 10 Basak and Panda studied the anisotropic constants of EDD and AA5052 sheet metals by comparing the data obtained from uniaxial tensile test and compression test with Hill48 and Yld2000-2D yield models. Furthermore, the deformation behavior was analytically evaluated using Marciniak-Kuczynski (MK) and Bao-Wierzbicki (BW) models and compared with results from punch-stretching test.…”

Section: Introductionmentioning

confidence: 99%

A method and apparatus for determination of the ultrasonic-assisted forming limit diagram

Najafizadeh

Rajabi

Hashemi

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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It was recently demonstrated that ultrasonic vibrations could result in lower forming forces and a better surface finish in a wide range of metal forming processes. The Nakazima stretch-forming test is a long-established experimental procedure for the formability evaluation of sheet metals. Today, the development of a standard test is critical for assessing sheet metals’ formability enhancement due to ultrasonic vibrations, which can potentially unlock the material selection limit in various manufacturing applications. This study aims to present a method and apparatus for effectuating the forming limit diagram (FLD). At the same time, high-frequency ultrasonic vibrations are combined with the movement of the forming tool. Taking St14 steel as an example, the mechanical and microstructural properties such as formability, Micro-Vickers hardness, and grain sizes were systematically investigated. Furthermore, the conventional FLD, as well as the novel “Ultrasonic-Assisted Forming Limit Diagram” (UA-FLD), were attained and compared with a nonlinear regression-based approach. The results have indicated that superimposing ultrasonic vibrations with the amplitude of 15µm at the frequency of 20 kHz to the tool would cause a notable enhancement in forming limit diagram, a maximum of 28% increase in hardness, and a 23% reduction in average grain size of the specimens.

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“…However, anisotropy of COF can only be determined using pin-on-disk test [4]. Apart from the friction conditions, the second important parameter determining the sheet deformability is the anisotropy of the mechanical properties of the sheet material [5]. The forming conditions that determine the geometric and shape quality of drawpieces depend on four groups of factors related to (1) lubrication conditions, (2) forming conditions, (3) phenomena related to the type of material being deformed, and (4) tool related factors.…”

Section: Introductionmentioning

confidence: 99%

Modelling Anisotropic Phenomena of Friction of Deep-Drawing Quality Steel Sheets Using Artificial Neural Networks

Trzepieciński

Lemu

Chodoła

et al. 2021

Advances in Materials Science

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This paper presents a method of determining the coefficient of friction in metal forming using multilayer perceptron based on experimental data obtained from the pin-on-disk tribometer. As test material, deep-drawing quality DC01, DC03 and DC05 steel sheets were used. The experimental results show that the coefficient of friction depends on the measured angle from the rolling direction and corresponds to the surface topography. The number of input variables of the artificial neural network was optimized using genetic algorithms. In this process, surface parameters of the sheet, sheet material parameters, friction conditions and pressure force were used as input parameters to train the artificial neural network. Some of the obtained results have pointed out that genetic algorithm can successfully be applied to optimize the training set. The trained multilayer perceptron predicted the value of the friction coefficient for the DC04 sheet. It was found that the tested steel sheet exhibits anisotropic tribological properties. The highest values of the coefficient of friction under dry friction conditions were registered for sheet DC05, which had the lowest value of the yield stress. Prediction results of coefficient of friction by multilayer perceptron were in qualitative and quantitative agreement with the experimental ones.

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A review on the evaluation of formability in sheet metal forming

Cited by 16 publications

References 72 publications

A comparative study on the effect of grid printing methods and camera hardware in automatic strain measurement through CGA

A comparative study on the effect of grid printing methods and camera hardware in automatic strain measurement through CGA

A method and apparatus for determination of the ultrasonic-assisted forming limit diagram

Modelling Anisotropic Phenomena of Friction of Deep-Drawing Quality Steel Sheets Using Artificial Neural Networks

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