This paper focuses on the modeling of metal response when subjected to sheet forming operation called cold plastic rolling (CPR). The CPR process is the fourth operation of hinge manufacturing in the industry. A 3D finite element (FE) model of the CPR process is built under ABAQUS/Explicit environment. A second simulation that takes into account the effect of the workpiece material history has been considered to improve the CPR model accuracy. Both proposed CPR process model results, in terms of values of CPR-die force vs. displacement, are compared with experimental ones. From the main results, it was found that the comparison between the experimental and the numerical findings, without taking into account the bending effect, shows a poor correlation. However, the reliability of CPR model is well proved when taking into account the workpiece residual stresses and plastic strain. Through simulation, the CPR-die force evolution and the friction coefficient effect are investigated in detail. The research results provide valuable guidelines for better understanding the deformation characteristics of CPR process.
The International Journal of Advanced Manufacturing Technology – Springer Journals
Published: Oct 23, 2017
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