Sheet metal forming massachusetts institute of technology. Bending force and springback in vdiebending of perforated. In this thesis we analyze the energy and environmental impacts of sheet metal manufacturing, focusing on the aerospace industry. The finite element simulation of metal forming processes is very useful to predict the strain, stress, working force and ductile failure.
For more information, the reader may consult schuler metal forming handbook 2. Forming sheet stretch forming is a fast, economical, and accurate way to form a large panel from a metal sheet. Jung 1 journal of materials engineering and performance volume 7, pages 479 490 1998 cite this article. However, this method of forming lacks flexibility and cost effectiveness.
In such cases, manual panel beating is typically undertaken for incremental forming of metal panels. Sheet metal is used in the production of materials ranging from tools, to hinges, automobiles etc. Progress in blankholder systems in the pulsating blankholder system the blankholder is subjected to a vibratory pulsating force. Stamping is used to form automotive body panels and. A sheet formed part is usually obtained through a number of operation phases. Ductile failure is defined as the initiation of cracks during the plastic. Incremental sheet forming isf process is an advanced flexible manufacturing process to produce complex 3d products. Thiruvengadam, harish, analysis of part consolidation techniques for automotive body in white panels based on advanced sheet metal forming technologies 2010. This study implemented sheet metal forming and fabrication machine tools that were tended by a robotic manipulator. Handbook of metalforming processes 1st edition by henry ericsson theis author 5. Sheet metal refers to metal that has a high surface area to volume ratio. Highmix, low volume lean manufacturing implementation and lot size optimization at an aerospace oem by jonathan m. Incremental sheet metal forming ismf has demonstrated its great potential to form. In recent years, enormous progress has been made in the analysis of forming of complex shapes using.
Sheet metal forming processes are widely used in the automotive industry to fabricate many components such as body panels, the structural members of the chassis and so on. Sheet metal forming processes university of florida. The gripping tool for the system will be designed later in another project and any optimization or further development of the system, if needed, will be. V forming cell abstract this field project study was performed at a manufacturer of residential heating products. Metal forming is the main method of making metal products and semifinished products. In this paper, a detailed theoretical treatment for a coupled thermomechanical finite element analysis of the sheet metal forming process has been presented. Design for manufacturability sheet metal guidelines. Study of dynamic explicit analysis in sheet metal forming. Deep drawing is one of the extensively used sheet metal forming processes in the industries to have mass production of cup shaped components in a very short time.
Pdf incremental sheet metal forming ismf has demonstrated its great potential to form. Wong and johnson 1988 investigated the amount of nonlinearity in loading and unloading. The process involves stretching the sheet to a calculated yield point and forming it over a. Most failures of ductile materials in metalforming processes occur due to material damage evolution void nucleation, growth, and coalescence. In incremental sheet metal forming the blank is incrementally deformed in to a desirable shape by hemispherical or ball.
Little work has been done on quantifying the environmental impacts and costs of sheet metal stamping. Sheet metal forming processes sheet metal processes can be broken down into two major classifications and one minor. The rate at which production increased, including metal forming, can be extracted from fig. In this work, we present models that can be used to predict the energy requirements, global warming potential, human health impacts, and costs of making drawn parts using zinc kirksite diesets and hydraulic or mechanical presses. In conventional forming process, the products are produced by dedicated tools. The present paper aims at a theoretical study of the forming limits of a sheet metal subjected to double strain path changes by using as reference material the aa6016t4 aluminum alloy sheet.
Challenges are to prevent stamped parts from wrinkling and tearing, to improve their dimensional accuracy, and to maintain consistency in the stamping process. Incremental metal forming processes in manufacturing springerlink. Importance of tool configuration in incremental sheet metal forming of difficult to. Galling wear detection and measurement in sheet metal forming. Rheaume submitted to the department of mechanical engineering and the sloan school of management on may 18, 2003 in partial fulfillment of the requirements for the degrees. Ductile failure is defined as the initiation of cracks during the plastic deformation. Experimental and numerical characterization of damage and.
Design for manufacturability sheet metal guidelines bends for the ease of manufacturing, multiple bends on the same plane should occur in the same direction. Journal of materials processing technology, volume 110, issue 1, march 2001 pages 3646. There exists a considerable body of literature on the analysis of sheet metal forming process. Analysis, design, and experiments for punch force control in. Sheet metal fabrication plays an important role in the metal manufacturing world. Some of the original topics have been omitted or given in an abbreviated form in appendices.
Thesis submitted in partial fulfillment of the requirements for the degree of doctor from the. Lindgren, cold roll forming of a uchannel made of high strength. Introduction to sheet metal fabrication meta lwork fabrci ation 2 youth explore trades skills terminology aluminum. To preclude the current flow to the machine tool, metal blank is sandwiched between two insulating sheets and are clamped peripherally in the fixture. They include a very wide range of consumer and industrial products, such as beverage cans, cookware, file. Progressive tool design and analysis for 49 lever 5 stage tools. Fixtureless automated incremental sheet metal forming core. Analysis and optimization of springback in sheet metal forming. Volume 14b on sheet forming is the second of two volumes on metalworking technology. In this work, we present models that can be used to predict the energy requirements. Fixtureless automated incremental sheet metal forming. Single point incremental forming spif is a sheet forming process with a simple setup.
A theoretical study of the effect of the double strain path. Sheet metal fabrication ranges from deep drawing, stamping, forming, and hydro forming, to highenergyrate forming herf to create desired shapes. Cheng laser forming lf is a highly flexible rapid prototyping and low volume manufacturing. This thesis deals with the improvement of numerical prediction of the springback.
International journal of machine tools and manufacture, 2008, vol. Highmix, lowvolume lean manufacturing implementation and lot size optimization at an aerospace oem by jonathan m. This thesis presents research that has been carried out at the department of. It delimits the maximal possible deformation in forming processes. Bruno ninaber van eyben, in manufacturing and design, 2014. Journal of materials processing technology, volumes 153154. Formability studies sheet metal basics sheet metal forming involves a wide range of processes that manufacture parts for a vast amount of purposes, both seen and unseen.
Importance of tool configuration in incremental sheet metal. Material characterisation for analyses of titanium sheet. Type of forming process rolling, forging, sheet metal drawing, etc. Experimental and computational investigation of the roll. Sheet metal forming is a manufacturing process with the purpose of forming a sheet blank through plastic deformation. Applications are necessary in the process to identify and determine the. Sheet metal forming lies right at the heart of industrial manufacturing. Pdf deformation mechanisms and process planning in double. Padghan, force analysis of metal sheet in bending operation on sheet bending machine.
Highmix, lowvolume lean manufacturing implementation and. Improvement of springback prediction in sheet metal forming core. Sheet metal stamping is one of the primary manufacturing processes because of its high speed and low cost for high volume production. Unfortunately, poor drawability of some materials makes it. This is followed by the thesis structure and chapter summary. Study of dynamic explicit analysis in sheet metal forming processes using faster punch velocity and mass scaling scheme d. At the same time, mechanical, action mediabased as well as laserbased forming operations were taken. Springback calibration of sheet metal components using.
An energy and environmental analysis of aerospace sheet metal. Sheet metal forming methods are one of the most popular. Lindgren, finite element model of roll forming of a uchannel pro. Sheet metal is metal formed by an industrial process into thin, flat pieces. Applications are necessary in the process to identify and determine the appropriate degree of complexity of suitable experiments, material models and validation tests for the numerical prediction of sheet metal forming. The forming force is dramatically reduced due to the local deformation and. Rheaume submitted to the department of mechanical engineering and the sloan. The current article examines the modified yield function of. Nov 02, 2016 little work has been done on quantifying the environmental impacts and costs of sheet metal stamping. Diebased forming is a technology used by many industries to form metal panels. Study on fatigue life and fracture toughness of sheet metal after laser forming abstract by jun zhang, m. Highmix, lowvolume lean manufacturing implementation. Robot cell for incremental forming of aluminum metal sheet schafer and. Analysis, design, and experiments for punch force control.
Deep drawing is one of the extensively used sheet metal forming processes in the industries to have. An economic evaluation of sheet hydroforming and low volume. Although the process is simple, it can cause several technical problems in production such as prediction of springback, punch load and fracture in stretched surfaces farsi and arezoo, 2007. An environmental and cost analysis of stamping sheet metal. Rapid prototyping by single point incremental forming of sheet metal. Plate metalwork is the manipulation of metal plate over 3. The thesis deals with high strength steels and one stainless steel, numerical simulation. Continuing our focus on sheet metal forming, this issue of dfm guidebook focuses on design guidelines for bend. Sheet metal forming involves a wide range of processes that manufacture.
The simulation of plastic instability is carried out through the marciniakkuczynski analysis. Major and minor strains were acquired using strain point data through circular grid analysis technique, which is widely used in sheet metal forming. Sheet metal work stock, used for sheet metal processes, is usually formed by rolling and comes in coils. The current article examines the modified yield function of liao et al. The cold roll forming, high volume production process, plays an important role in sheet metal forming processes used to create wide variety of product. Friction is the main phenomenon that has a huge influence on the flow behavior of deformed material in sheet metal forming operations. Conventional sheet metal forming of the titanium alloy ti6242 therefore functions as an application in the research project. A sheet formed part is usually obtained through a number of operation phases final surface. Finite element simulation of sheet metal forming is a wellestablished tool which is used in. A first stage where the volume of the part is generated a second stage where the geometrical details are formed reverse drawing in the first stage. Extending origami technique to fold forming of sheet metal products a dissertation presented to the graduate school of clemson university in partial fulfillment of the requirements for.
The keynote paper, sheet metal forming at elevated temperatures, incorporated an overview of research activities as well as primary industrial applications where temperature is used specifically as a process parameter for sheet metal forming. Finite element assisted prediction of ductile fracture in. In this section a short introduction to the stamping and forming process will be given. Schrauth, chris perification process for implementation of robotictended sheet metal. Evolution of manufacturing can be broadly divided into manual. Fundamentals of metal forming overview of metal forming. Manual panel forming is a highly skilled operation with very little documentation and is disappearing due to nonobservance and a lack of. Incremental sheet forming applied to the manufacturing of. Forming limit diagram fld, a representation of the critical combination of the principal surface strains, is an important concept utilized for the evaluation of the formability of sheet metals. In almost all products that consist of multiple parts, at least one of these parts will be formed out of sheet metal, even if it is as simple as a bent strip of phosphor bronze to conduct electricity in a switch, or a piece. Mishra, in friction stir processing for enhanced low temperature formability, 2014. Deformation mechanism analysis of single point incremental sheet. Sheet metal forming processes mustansiriyah university.
Sheet metal forming, which is often referred to as stamping, is a process in which a piece of sheet metal, referred to as the blank, is formed by stretching between a punch and. Purchase mechanics of sheet metal forming 2nd edition. Any forming process system is composed of the machine, the work piece. One of the most common processes in sheet metal forming is bending. In deep drawing, a flat blank of sheet metal is shaped by the action of a. Master thesis sheet metal forming simulations with fem. The tool could be guided by a cnc milling machine, robot.
An and modelling approach for improving of the cold roll. Finite element simulation of metal forming processes in abaqus. View sheet metal forming research papers on academia. Pdf incremental metal forming processes in manufacturing.
The positive effect of nitrogen alloying of tool steels used. Mechanics of sheet metal forming college of engineering. Sheet metal is one of the fundamental forms used in metalworking, and it can be cut and bent into a variety of shapes. Challenges are to prevent stamped parts from wrinkling and. Sheet metal forming is quite common for making shaped. If you design sheet metal parts, you may know that bend relief is a notch cut made into the. Incremental forming technologies, currently in practice, lack adaptability as they require substantial fixtures and dedicated tools. Nilsson, 20, the e ects of forming history on sheet metal assembly, international journal of material forming, doi. The work in this thesis explores various aspects of isf research, although the most. More than 90% of smelted metal is processed by different methods of metal forming. Finite element simulation of metal forming processes in.
973 1426 719 1336 23 1136 999 193 1338 1187 608 1311 164 1337 837 1631 908 835 887 1472 879 1409 155 540 1523 159 225 1268 1264 1079 67 1500 1566 710 698 633 673 1032 365 665 621 334 1177 1051 860 118 748 59 971