Material flow control in high pressure sheet metal forming of large area parts with complex geometry details

Date

2005-12-01

Author

Trompeter, M
Onder, E
Homberg, W
Tekkaya, E
Kleiner, M

Metadata

Show full item record

This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Item Usage Stats

94
views

0
downloads

Working media based forming processes show advantages compared to the conventional deep drawing in the range of sheet metal parts with complex geometry details. By High Pressure Sheet Metal Forming (HBU), complex parts can be formed with reduced tool costs, fewer process steps, and improved part properties, particularly by the use of high strength steels. In order to use these advantages to full capacity, the material flow into the area of the geometry details needs to be optimised. The key element for the material flow control is a multi-point blank holder. In combination with flange draw-in sensors, a closed loop flange draw-in control can be built up which guarantees a reproducible material flow and, consequently, defined part properties. Furthermore, a favourable pre-distribution of sheet metal material can be reached which leads to a widening of the process limits. Considering a large area sheet metal part with a complex door handle element as example, strategies for the material flow control will be discussed in this paper. The conclusions are based on FE-simulations as well as experimental findings.

Subject Keywords

Sheet metal hydroforming, Process control, Material flow, Oscillating blank holder forces, 100 MN hydroform press, FEM

URI

https://hdl.handle.net/11511/67926

Journal

STEEL RESEARCH INTERNATIONAL

DOI

https://doi.org/10.1002/srin.200506114

Collections

Department of Mechanical Engineering, Article

Suggestions

OpenMETU
Core

Failure analysis of tapered composite structures under tensile loading Çelik, Ozan; Parnas, Kemal Levend; Department of Mechanical Engineering (2016) A three dimensional finite element modeling approach is used to evaluate the effects of preliminary design variables on the performance of tapered composite laminates under tensile loading. Hashin failure criteria combined with a progressive failure algorithm is used for in-plane failure mechanisms and cohesive zone method is used for out-of-plane failures. The modeling approach is validated by a comparison with experimental results from literature. The validated model is used to examine various design vari...
Magnetic and Structural Analysis of a Transverse Flux Claw Pole Linear Machine Keysan, Ozan; Mueller, Markus A. (2013-01-01) This paper details the design and testing of a novel transverse flux claw pole linear machine suitable for large superconducting generators. The machine utilises a modular claw pole transducer design with a stationary field winding which eliminates the need for cryogenic couplers and electrical brushes for a superconducting machine. The results from this prototype will enable a better understanding of the electromagnetic and mechanical structures before embarking on a more costly super-conducting design. Th...
Investigation of the deep drawability of steel and aluminum sheets by finite element simulation Sönmez, Çağlar; Gür, Cemil Hakan; Department of Metallurgical and Materials Engineering (2005) Sheet metal forming processes, especially deep drawing processes give diverse results by various materials. Extreme differences occur between steel sheets and aluminum sheets. The main causes of this variance are anisotropy, elastic modulus and microscopic material properties. The aim of this thesis is to evaluate the deep drawing properties and also to develop suitable process parameters for aluminum and steel sheets by finite element simulation. In the simulation, the commercial dynamic-explicit code PAM-...
Thermal fracture analysis of orthotropic functionally graded materials using an equivalent domain integral approach Dağ, Serkan (2006-12-01) A new computational method based on the equivalent domain integral (EDI) is developed for mode I fracture analysis of orthotropic functionally graded materials (FGMs) subjected to thermal stresses. By using the constitutive relations of plane orthotropic thermoelasticity, generalized definition of the J-integral is converted to an equivalent domain integral to calculate the thermal stress intensity factor. In the formulation of the EDI approach, all the required thermomechanical properties are assumed to ha...
Structural coupling of two nonlinear structures Tepe, Çağrı; Ciğeroğlu, Ender; Department of Mechanical Engineering (2018) In mechanical design, modelling and analysis of a complex structure can be simplified with dividing the structure into substructures; therefore, any change in the structure can be addressed easily which is referred as “structural coupling”. Utilization of proper coupling techniques, it is possible to understand the behavior of the whole structure by considering the behavior of its substructures. For linear structures, coupling is a common technique; however, in most of the engineering structures, nonlineari...

Citation Formats

M. Trompeter, E. Onder, W. Homberg, E. Tekkaya, and M. Kleiner, “Material flow control in high pressure sheet metal forming of large area parts with complex geometry details,” STEEL RESEARCH INTERNATIONAL, pp. 905–910, 2005, Accessed: 00, 2020. [Online]. Available: https://hdl.handle.net/11511/67926.