Choosing an Efficient Method for Forming Parts by Means of an Engineering Analysis Performed with the Use of a CAE System

Abstract

The possibility of forming parts by different methods is analyzed. The formation of defects is modeled and ways are proposed for eliminating them. A conclusion is reached as to the most efficient method of making the part that is discussed. Keywords: pneumo-thermal forming of sheetmetal parts, drop-hammer drawing, elastoforming, drawing in rigid dies.One of the most important problems in aeronautical and mechanical engineering is finding an efficient method for forming parts from flat-rolled products. The forming method is chosen on the basis of the experience and knowledge of the engineer, i.e., the effectiveness of the chosen solution depends on the human factor. Such dependence is unacceptable in modern industry. In this article, we will conduct a virtual search for an efficient manufacturing variant to make a part with the use of CAE systems.We chose a part ( Fig. 1) with a complex three-dimensional shape to analyze different forming methods. The double-curvature part contains two channels and two sides oriented in the same direction; the material of the part is alloy AMg6. The part's thickness is 0.8 mm.An efficient forming method will be sought in the PAM-STAMP 2G system developed by the French Company ESI Group to perform engineering analyses for sheet stamping.We will examine seven variants for forming the part. 1. Drawing out on a stamping hammer -the process most commonly used to make sheetmetal parts with a complex surface. The following assumptions were made during the modeling operation: a) the effect of deformation rate on stress is ignored; b) the end liners are modeled as having the properties of a material which can be described by the Mooney-Rivlin model; c) the end of impact is determined by the limit on the travel of the punch; d) the plastic part of the flow curve is expressed through the function in the Krupkowsky law (σ = K(ε 0 + ε p ) n , where σ is the running level of stress; K is the strength coefficient; ε 0 and ε p are the initial and running levels of plastic strain; and n is the strain-hardening coefficient); e) Hill model 48 is chosen to describe the yield surface; and f) the initial thickness of the semifinished product is 1 mm.

The Possibility of Modeling Parts in Production Technology

“…To choose the optimum method for manufacturing of the workpiece, it is necessary to analyze the influence of several factors on the part. They include material (Shmakov et al, 2019), shape, overall dimensions (KolmogortsevI et al, 2016), weight, technical requirements, volume and serial production (Cheslavskaya et al, 2015), material utilization ratio (Competence Center "Technological Modeling", 2019). Eventually, we should choose the method providing the maximum manufacturability, minimum labor input and lowest cost price.…”

The inverse task solution for the calculation of sweeps of sheet parts by integral geometry

“…5 show the distribution of thickness and strain after the second transition. The calculation results show that the parts have a large elastic response after forming due to the low strain [1] (Fig. 6).…”

“…At present great difficulties in the aircraft construction are caused by the production of parts in the aerodynamic contour of the complex spatial form and the small relative deformations [1,2]. Some of these parts can be produced by applying bending with superimposed stretch forming or as they say in the aircraft construction "the covering".…”

Using a Discrete Product Model in the Technological Preparation of Production

“…После базирования ее необходимо закрепить [2,3]. Для обеспечения неподвижности в выбранной системе координат на нее необходимо наложить шесть двусторонних геометрических связей, для созда-ния которых нужен комплект опорных точек.…”