Prediction of wrinkling and springback in sheet metal forming

Neto, Diogo M.; Oliveira, M. C.; Alves, J. L.; Santos, Abel D.; Menezes, L.F.

doi:10.1051/matecconf/20168003005

Cited by 3 publications

(8 citation statements)

References 30 publications

(36 reference statements)

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“…In this study, two finite element codes are used to perform the BM2. One code is AutoForm (R6, AutoForm Engineering GmbH, Wilen bei Wollerau, Switzerland) [9], whose results will be labeled as AF-UP, and the other code is DD3IMP (v1.8, CEMMPRE, Coimbra, Portugal) [1,10], whose results are labeled as DD3-UC.…”

Section: Finite Element Methods Codes and Numerical Modelsmentioning

confidence: 99%

“…In modern manufacturing industries, sheet metal-forming processes are commonly used to produce complex parts. The major concerns of the automotive industry are environmental protection (requiring low fuel consumption and low exhaust emissions) and the safety specifications [1]. Therefore, newer materials or solutions are required to reduce the weight of the vehicle body structures and closures, such as aluminum alloys and high-strength steels.…”

Section: Introductionmentioning

confidence: 99%

“…In this benchmark, an aluminum AA6451-T4 blank with 3 mm thickness is stamped and trimmed before evaluating the final geometry of the obtained panel after springback. Two different models were considered using different FEM codes, AutoForm [9] and DD3IMP [1,10]. The springback results of the panel were analyzed in three different cross-sections and compared with experimental measurements from the deep-drawn part, available from the benchmark.…”

Section: Introductionmentioning

confidence: 99%

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Issues on the Correlation between Experimental and Numerical Results in Sheet Metal Forming Benchmarks

Amaral

Neto

Wagre

et al. 2020

Metals

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The validation of numerical models requires the comparison between numerical and experimental results, which has led to the development of benchmark tests in order to achieve a wider participation. In the sheet metal-forming research field, the benchmarks proposed by the Numisheet conference series are a reference, because they always represented a challenge for the numerical codes within the state of the art in the modeling of sheet metal forming. From the challenges proposed along the series of Numisheet benchmarks, the springback prediction has been frequently incorporated, and is still a motivation for the development and testing of accurate modeling strategies. In fact, springback prediction poses many challenges, because it is strongly influenced by numerical parameters such as the type, order, and integration scheme of the finite elements adopted, as well as the shape and size of the finite element mesh, in addition to the constitutive model. Moreover, its measurement also requires the definition of a fixture that should not influence the actual springback and the proper definition of the measurement locations and directions. This is the subject of this contribution, which analyzes the benchmark focused on springback prediction, proposed by the Numisheet 2016 committee. Numerical results are obtained with two different codes and comparisons are performed between both numerical and experimental data. The differences between numerical results are mainly dictated by the ambiguous definition of boundary conditions. The analysis of numerical and experimental springback results should rely on the use of global planes to ensure the objectivity and simplicity in the comparison. Therefore, the analysis gives an insight into issues related to the comparison of results in complex geometries involving springback, which in turn suggests some recommendations for similar future benchmarks.

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Section: Finite Element Methods Codes and Numerical Modelsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Issues on the Correlation between Experimental and Numerical Results in Sheet Metal Forming Benchmarks

Amaral

Neto

Wagre

et al. 2020

Metals

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“…The results showed that the parameter with the most substantial influence was blank holder force with the number is 56.98%, the punch radius was 30.12%, and the die radius was 12.90%. p-ISSN: 1410-2331 e-ISSN: 2460-1217 Numerical experiments and analysis of rail shapes with a high tendency to form a wrinkle on surface of flange has been conducted by [7]. The formation process consists of three phases.…”

Section: Materials Thickness Ratio (T R ) and 2 Drawing Ratio (M)mentioning

confidence: 99%

“…Deep drawing is one of the most widely used SMF processes for producing cylindrical cup and flange cup cylinder components in a high level of accuracy and quality. Cylindrical cup shapes and cylindrical flange cups with deep drawing processes are widely used for the production of major components in the automotive, household, and electronic industries [4,5,6,7]. In the deep drawing process, a sheet metal blank is drawn over a die cavity using a shaped punch.…”

Section: Introductionmentioning

confidence: 99%

Simulation and Experimental Investigation of Wrinkle Defect in Deep Drawing Process of Carbon Steel SPCC Shaped Cylinder Flange Cup

Mulyanto

Khaerudini

2020

Sinergi

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A Sheet Metal Forming (SMF) process, especially deep drawing, is one of the manufacturing processes that commonly used in the automotive industry. Compared with casting and forging, the SMF process has several advantages, including lesser weight materials and broader variations in shape that can be made. One of the problems in the SMF process is the wrinkling phenomenon, which can cause the size and appearance defects of sheet products. The wrinkle occurs because of the mechanical properties of the material, product geometry, and blank holder force (BHF). Several variations of BHF were applied in these simulations and experiments to eliminate the wrinkle defects of cylinder flange cup test products. The characteristic of the cylinder flange cup is from the cold-rolled coiled steel plate (SPCC) type of material with a thickness of 0.8 and 1.0 mm, the height of 10 mm, the inner diameter of 58 mm, and flange diameter of 76 mm. Simple simulations of the SMF process were carried out by using Solidworks with version 2017, and the experiment was carried out at a 600 kN press with a punch velocity of 40 strokes per minute and blank holder force variations from 0 to 21 kN. The experimental data performed with a single die on a flanged cup cylindrical test material shows that the higher the blank holder force (BHF) number, the smaller the wrinkle defect, and it can be eliminated starting from the BHF number of 15 kN.

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Study the Influence of Geometric Parameters on Springback in T-Section Aluminum Alloy Window Trim Strip Sheets Forming

Zhu

Zhao

et al. 2018

MSF

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The T-section aluminum alloy window trim strip sheets are used to improve vehicle appearance. As the mobile scenery line, these window trim strips with claws need high forming accuracy to meet good assembly quality requirement. The top portion of the T-section sheet is stamped to form an edge flange structure. Springback control is essential in forming process. In this paper, the influence of the window trim strip geometric parameters on forming springback is studied. Some finite element models of the process were built with the Dynaform software. The simulation results were verified experimentally. The main conclusions include as belows: The different heights of the stiffeners part in T-section change the stiffness of the part. Although the stiffeners part does not participate in the forming, it also has springback in the forming process. So, it is necessary to study the influence of the flanging part width (W) and the stiffeners part height (H) of the T-section on springback. We set W to 15 mm and change the value of H value according to the real product. The value of springback increases with the increase of H value in the beginning. After ratio of H/W increases to 0.6, the value of springback fluctuates with the increase of H value. When ratio of H/W is about 0.5, the springback values are mostly less than ± 0.5 mm in key sections, which is acceptable.

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Prediction of wrinkling and springback in sheet metal forming

Cited by 3 publications

References 30 publications

Issues on the Correlation between Experimental and Numerical Results in Sheet Metal Forming Benchmarks

Issues on the Correlation between Experimental and Numerical Results in Sheet Metal Forming Benchmarks

Simulation and Experimental Investigation of Wrinkle Defect in Deep Drawing Process of Carbon Steel SPCC Shaped Cylinder Flange Cup

Study the Influence of Geometric Parameters on Springback in T-Section Aluminum Alloy Window Trim Strip Sheets Forming

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