Ironing force modeling analysis on aluminum cup using CATIA V5

Faizin, Akhmad; Wahjudi, Arif; Batan, Ide; Pramono, Agus Sigit

doi:10.1063/1.5046270

Cited by 2 publications

(3 citation statements)

References 14 publications

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“…The results show that at the same TRR and varying die angle, the stresses that occur in the cup vary. At the higher TRR, the higher the voltage [10]. Based on the results of this study, further research is needed on the effect of TRR and die angle on residual stress.…”

Section: Literature Review and Problem Statementmentioning

confidence: 87%

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: 87%

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

Self Cite

View full text Add to dashboard Cite

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“…The outer wall thickness was reduced with varying the TRR (thickness reduction ratio) through a die ring with various die angles. Based on this stress, the most optimal condition was selected [12]. Mukhtar et al conducted a simulation of an ironing process for a caliber bullet case to determine the minimum forming force on a variety of die angle and thickness reduction rates [13].…”

Section: Figure 2 Dimensions Of the Liner For The Type II Cng Vesselmentioning

confidence: 99%

“…The reduction ratio of the cross sectional area (RA) in one stage is defined as Equation (12). A 0 is the cross sectional area before forming, and A f is the cross sectional area after forming.…”

Section: Existing Ddi Processmentioning

confidence: 99%

Design of a Combined Redrawing-Ironing Process to Manufacture a CNG Pressure Vessel Liner

Park

Kwak

et al. 2021

Applied Sciences

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The liner of a compressed natural gas pressure vessel is manufactured by D.D.I. (Deep Drawing and Ironing), which is a continuous process that uses deep drawing to reduce the diameter of a billet and ironing to reduce the thickness of the billet. In the second stage of the existing D.D.I. process, drawing and two steps of ironing have been performed separately with different dies, which requires a long processing time, high manufacturing cost, and installation space. To solve the above problems, this study suggests a new second stage using a combined redrawing-ironing die. A theoretical formula to calculate the forming load of the combined redrawing-ironing process was established and verified with finite element analysis results. The forming load, maximum thickness reduction ratio in the second stage, and forming defects in the third stage were analyzed by varying the redrawing-ironing ratio in the second stage. The results show that the number of dyes (3 → 1), punch diameter (394.1 mm → 383 mm), and processing time (39.8 s → 20 s) in the second stage were obtained to save production time and cost.

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Ironing force modeling analysis on aluminum cup using CATIA V5

Cited by 2 publications

References 14 publications

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

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

Design of a Combined Redrawing-Ironing Process to Manufacture a CNG Pressure Vessel Liner

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