Pressure Optimization and Failure Prediction for Deep Drawing Process of Sheet Metal Products: A Case Study

Pressure Optimization and Failure Prediction for Deep Drawing Process of Sheet Metal Products: A... Sheet metal forming is an important process in most industries where large-sized products are deep drawn for obtaining the complex shape of products at higher productivity rates. During deep drawing process industries often experience failures like wrinkling, fracture, tearing and earring of the sheet metal. Different aspects of these failures are discussed in this paper so as to minimize these failures. The methodology followed is: adopting a standard theoretical design; performing a computational analysis using software package ANSYS and comparing experimental results with our simulations. A particular set of industrial data is used for this analysis which helps to evaluate the causes of failures. It is determined that low pressure leads to wrinkling on/nearby the flange area, while excess pressure causes sudden fracture or tearing through the sides/wall surface. Also optimum pressure is determined experimentally for standard commercial products so as to avoid the failures during the process. The simulation results of ANSYS are in conformance with the experimental data showing the maximum thickness reduction ratio and the maximum depth of draw. Failures can then be predicted with a good accuracy for different designs of products from simulated values. http://www.deepdyve.com/assets/images/DeepDyve-Logo-lg.png Journal of Failure Analysis and Prevention Springer Journals

Pressure Optimization and Failure Prediction for Deep Drawing Process of Sheet Metal Products: A Case Study

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Publisher
Springer Journals
Copyright
Copyright © 2018 by ASM International
Subject
Materials Science; Tribology, Corrosion and Coatings; Characterization and Evaluation of Materials; Classical Mechanics; Structural Mechanics; Quality Control, Reliability, Safety and Risk
ISSN
1547-7029
eISSN
1864-1245
D.O.I.
10.1007/s11668-018-0485-6
Publisher site
See Article on Publisher Site

Abstract

Sheet metal forming is an important process in most industries where large-sized products are deep drawn for obtaining the complex shape of products at higher productivity rates. During deep drawing process industries often experience failures like wrinkling, fracture, tearing and earring of the sheet metal. Different aspects of these failures are discussed in this paper so as to minimize these failures. The methodology followed is: adopting a standard theoretical design; performing a computational analysis using software package ANSYS and comparing experimental results with our simulations. A particular set of industrial data is used for this analysis which helps to evaluate the causes of failures. It is determined that low pressure leads to wrinkling on/nearby the flange area, while excess pressure causes sudden fracture or tearing through the sides/wall surface. Also optimum pressure is determined experimentally for standard commercial products so as to avoid the failures during the process. The simulation results of ANSYS are in conformance with the experimental data showing the maximum thickness reduction ratio and the maximum depth of draw. Failures can then be predicted with a good accuracy for different designs of products from simulated values.

Journal

Journal of Failure Analysis and PreventionSpringer Journals

Published: Jun 4, 2018

References

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