Three Dimensional Finite Element Simulation of Sheet Metal Blanking Process

Abstract

The shearing process such as the blanking of sheet metals has been used often to prepare workpieces for subsequent forming operations. The use of FEM simulation is increasing for investigation and optimizing the blanking process. In the current literature a blanking FEM simulations for the limited capability and large computational cost of the three dimensional (3D) analysis has been largely limited to two dimensional (2D) plane axis-symmetry problems. However, a significant progress in modelling which takes into account the influence of real material (e.g. microstructure of the material), physical and technological conditions can be obtained by using 3D numerical analysis methods in this area. The objective of this paper is to present 3D finite element analysis of the ductile fracture, strain distribution and stress in blanking process with the assumption geometrical and physical nonlinearities. The physical, mathematical and computer model of the process are elaborated. Dynamic effects, mechanical coupling, constitutive damage law and contact friction are taken into account. The application in ANSYS/LS-DYNA program is elaborated. The effect of the main process parameter a blanking clearance on the deformation of 1018 steel and quality of the blanks sheared edge is analyzed. The results of computer simulations can be used to forecasting quality of the final parts optimization.

Modeling and Experimental Analysis of Shear-Slitting of AA6111-T4 Aluminum Alloy Sheet

“…The analysis of the results shows that both the FEM and SPH methods accurately predict the characteristic features of the cut edge. The highest accuracy was obtained in The Johnson-Cook constitutive equation used in this study, allows to determine the dependence of yield stress on plastic deformation, taking into account the damage of the material [47,[61][62][63][64]. The model considers the impact of strain rate and temperature on the yield stress values according to the relationship:…”

“…The Johnson-Cook constitutive equation used in this study, allows to determine the dependence of yield stress on plastic deformation, taking into account the damage of the material [ 47 , 61 , 62 , 63 , 64 ]. The model considers the impact of strain rate and temperature on the yield stress values according to the relationship: where A , B , C , n , and m are the Johnson-Cook constitutive model constants, ε is the equivalent plastic strain, is the normalized effective plastic strain rate, and σ Y is the yield stress [ 47 ], T is the workpiece temperature, T m is the material melting temperature, T r is the room temperature.…”

“…The Johnson-Cook constitutive equation used in this study, allows to determine the dependence of yield stress on plastic deformation, taking into account the damage of the material [47,[61][62][63][64]. The model considers the impact of strain rate and temperature on the yield stress values according to the relationship:…”

Efficiency of Tool Steel Cutting by Water Jet with Recycled Abrasive Materials

“…Abrasive water jet (AWJ) and pulsating water jet (PWJ) treatment [ 4 , 5 ] do not have these weaknesses. An additional benefit of WJ technology is its environmental friendliness because among the methods of machining only plastic processing [ 6 , 7 ] and AWJ treatment [ 8 ] can meet these requirements.…”

Modelling and analysis of the technological processes using finite element method

“…At Department of Technical Mechanics at the Faculty of Mechanical Engineering of the Koszalin University of Technology were developed applications on the system ANSYS (APDL language), which allow a comprehensive time analysis for deformation (displacement, velocity, strain, strain rate), stresses and boundary condition in contact zone tool-object occurring in the object, both the spatial conditions as well as plane, in the processes technological precision machining parts ( Fig. 1): cutting processes [8,36,37,38,45,47,55,56,62,63,66,74], turning processes [20,34,57,75], burnishing rolling processes [1, 2, 3, 6, 7, 11, 17, 22, 28, 29 ,31-33, 36, 46, 49, 51, 60, 61, 65, 71, 73, 76-78], sliding burnishing [43,53,57,58,68], cutting by an abrasive single grain [12,14,19,21,24,25,33,39,40,72], embossing [12,23,30,50,70], thread rolling [1,2,4,5,9,10,…”