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8/12/2019 11 Selected Research Resu
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ERCNSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2004. All rights reserved.1
Selected Research Results in Stamping,Hydroforming and Forging
Selected Research Results in Stamping,Hydroforming and Forging
byDr. Taylan Altan, Professor and Director, [[email protected]]
Engineering Research Center for Net Shape Manufacturing (ERC/NSM)Columbus, Ohio, USA
Phone: 614-292-6468, Fax: 614-292-7219www.ercnsm.org
Prepared forInternational Conference
INNOVATIONS IN METAL FORMING23-24 September, 2004 - Brescia, Italy
ERCNSM
© Copyright Engineering Research Center for Net Shape Manufacturing, 2004. All rights reserved.2
OutlineOutline
IntroductionIntroductionStamping ResearchStamping ResearchHydroforming ResearchHydroforming ResearchForging ResearchForging ResearchSummary and Future Outlook Summary and Future Outlook
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© Copyright Engineering Research Center for Net Shape Manufacturing, 2004. All rights reserved.3
Introduction
Stamping Hydroforming MachiningForging
Research for Industry and Government
1) Material characterization <flow stress & formability>2) Tribology < friction,lubrication & wear >3) Process Modeling/Tool and Process Design4) Short Courses/Training for Industry and Students
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StampingStampingResearchResearch
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ERC/NSM Activities in StampingERC/NSM Activities in Stamping
1. Materials1. MaterialsDetermination of material flow stress (true stress - true strain) data at roomtemperature, under bi-axial state of stress, using Viscous Pressure Bulge test.
2. Tribology (Friction, Tool Wear)2. Tribology (Friction, Tool Wear)Determination of friction coefficient for use in FE simulations, using LimitingDome Height, Modified Limiting Dome Height, and Drawing and Ironing tests.Performance evaluation of various stamping lubricants (at room and elevatedtemperatures) to determine the best suitable lubricant for a particularapplication.
3. Process Modeling / Tool and Process Design3. Process Modeling / Tool and Process DesignDetermination of optimum constant / variable blank holder force profiles forstamping using FEMDetermination of blank shapes and process sequence for progressive diestamping using FEMDesign of warm sheet forming process of Mg & Al alloy sheets using FEMDesign of mechanical joining process (clinching / crimping) using FEM
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Real time measurement of instantaneous pressure and domeheight
Potentiometer
PressureTransducer
PunchLower
Die
Upper Die
ViscousMedium
Cushion Force
Moves with pressram
Moves with pressram
Stationary
Viscous Pressure Bulge Test- Sheet materials -
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Material : 1050 steel
0.0
200.0
400.0
600.0
800.0
1000.0
1200.0
1400.0
1600.0
0.000 0.050 0.100 0.150 0.200 0.250 0.300 0.350
True Strain
T r u e
S t r e s s
[ M P a
]
Tensile test
VPB test
Larger strains compared to tensile test
Flow Stress Curve
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Initial blank
(Circular blank with hole at thecenter)
Stretched blank
(Change in hole diameter)
Punch
Die
Clamping ring
Tribology/Modified LDH test
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Drawing and Ironing Test - Principle and Tooling
Tribology/Drawing and Ironing Test
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Issues with Multi-point Cushion Systems
..…
BHF for cushion pin 1
0
80
160
240
320
400
480
0 10 20 30 40 50 60Punch Stroke (mm)
B l a n
k H o
l d e r
F o r c e
( k N
?
BHF for cushion pin 15
0
80
160
240
320
400
480
0 10 20 30 40 50 60Punch Stroke (mm)
B l a n
k H o
l d e r
F o r c e
( k N
?Problem: How to determine the variation of
BHF for each cushion pin ?
Cushion pin 15
Cushion pin 1
FE Simulation for Variable BHF determination
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Inputs required
FEA SoftwareFEA Software(PAM-STAMP, LS-DYNA)
SoftwareSoftwaredeveloped atdeveloped at
ERC/NSM for BHFERC/NSM for BHFdeterminationdetermination
• Tool geometry (CAD)• Material properties• Process conditions
0
80
160
240
320
400
480
0 10 20 30 40 50 60Punch Stroke (mm)
B l a n
k H o
l d e r
F o r c e
( k N )
BHF for cushion pin 1
0
80
160
240
320
400
480
0 10 20 30 40 50 60
Punch Stroke (mm)
B l a n
k H o
l d e r
F o r c e
( k N )
BHF for cushion pin 2
0
80
160
240
320
400
480
0 10 20 30 40 50 60Punch Stroke (mm)
B l a n
k H o
l d e r
F o r c e
( k N )
BHF for cushion pin n
• Quality control parameters(wrinkling, thinning)
• Forming depth of the part• No. of cushion cylinders (n)
• Variation of BHF required− Constant in location and stroke− Constant in location, variable with stroke− Variable in location, constant with stroke
− Variable in location and stroke
FE Simulation for Variable BHF determination
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Stage 1
Stage 2
Stage 3
Stage 4
Stage 5
Stage 6
Stage 7
Stage 8
Stage 1
Stage 2
Stage 3
Stage 4
Stage 5
Stage 6
Stage 7
Stage 8
Process Modeling/Progressive forming sequencedesign for deep drawing of round parts
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Sheet Hydroforming of Large Al Alloy Reflectors
Sheet Hydroforming of Large Al Alloy Reflectors
• Design sheet hydroforming process to manufacture large reflectors (6m/12m Ф )
to meet the desired accuracy on the inner surface.
• Identify locations for cutting and assembly of large reflectors to reduce
distortion due to residual stresses.
• Quantify effect of process parameters such as (material properties, friction,
initial sheet flatness, clamping methods) on hydroformed part dimensions.
UpperDie
LowerDie
Sheet
Finite element modelSchematic of hydroforming operation
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© Copyright Engineering Research Center for Net Shape Manufacturing, 2004. All rights reserved.14 AIDA & ERC/NSMPtU Darmstadt
Elevated Temperature
Hydraulic Bulge Test
Mg & Al Sheet Forming at Elevated
Temperature
Warm Forming Tool
• Hydraulic bulge tests at various temperatures and strain rates to determine theflow stress of Mg AZ31-O alloy.
• Determination of optimum process variables and tool temperatures to obtain thehighest possible Limiting Draw Ratio by modifying initial temperatures of thepunch, die, die ring and blank holder, initial blank temperature and ram dwelltime, and blank holder force
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Servo Motor PressServo Motor Press
AIDA Digital servo former AIDA Digital servo formerCourtesy : Aida Engineering, Japan
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Process Modeling/Design of Fastener Clinching
Objective: Leak proof assembly (without holes) of fastener with sheet
Design requirement : Ability to withstand ~ 10 kN force
Final clinched assemblyGeometry at start of clinching
Punch
Fastener Fastener
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Process Modeling/FE Simulation of Fastener Clinching
Click to view animation
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HydroformingHydroformingResearchResearch
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ERC/NSM Activities in Tube HydroformingERC/NSM Activities in Tube Hydroforming
1. Materials1. MaterialsDetermination of material flow stress data for tubular materials withHydraulic Bulge Test at room temperatureDetermination of material flow stress data at elevated temperatures
2. Tribology (Friction, Tool Wear)2. Tribology (Friction, Tool Wear)Improvement of Tribological Conditions in Tube Hydroforming by UsingEnvironmentally Friendly Lubricant Systems and Textured Tubes
Viability of the Twist Compression Test for Screening Tube HydroformingLubricants
3. Process Modeling / Tool and Process Design3. Process Modeling / Tool and Process DesignSimulation of T shape tube hydroformingDesign of warm hydroforming process of Magnesium and Aluminum alloytubes.
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Materials/Flow Stress and Formability -Hydraulic Tube Bulge Test -
Hydraulic Bulge Test Equipment
Determination of flow stress of tubes for Hydroforming
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Tribology/Friction and Lubrication
Friction conditions at different contact locations
Due to different tribological conditions at the Guiding, Transition andExpansion zones, different lubrication tests are needed.
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Load Cell
PressureTransducer
Rod
Tube
Die-Insert
pi
Fa Fa
Ff pi
Fa Fa
Ff
saxsax
FFR FFR FFR FFR
G o o d
l u b r i c a
t i o n
B a d l u
b r i c a
t i o n
Tribology/Tooling for LubricationTest - Guiding Zone -
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Tribology/Tooling for LubricationTest - Expansion Zone -
Pear Shaped Expansion Test
68
68.5
69
69.5
70
70.5
71
71.5
72
72.5
Lub A Lub E Lub D Lub B No Lub
Lubricants
P r o
t r u s
i o n
h e
i g h t P H [ m m
]Specimen material SS304
Increasing interface friction
PH
Increasing interfacefriction
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© Copyright Engineering Research Center for Net Shape Manufacturing, 2004. All rights reserved.24
Tribology/ Twist CompressionTwist CompressionTest (TCT)Test (TCT) -- Principle of OperationPrinciple of Operation --
F r
T
*=µ
r
T
F
Before Test After Test
Material: AISI 1010 CRPressure: 500 bar
Sliding Velocity: 17 mm/sSliding Length: 160 mm
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Process Modeling /THF of T ShapeProcess Modeling /THF of T Shape
Part Name:Part Name: T fittingT fitting
Software:Software: DEFORM3DDEFORM3D
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Process Modeling /THF of T ShapeProcess Modeling /THF of T Shape
Part Name:Part Name: T fittingT fitting
Software:Software: DEFORM3DDEFORM3D
Click to view animation
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HydraulicCylinder
CylinderRod
Coolingadaptor
Clamping Die[Lower]
FormingDie
PunchTube
Clamping Die[Upper]
Prototype of Warm Tube Hydroforming System for Phase I
Tube Hydroforming System for Al andMg Tubes at Elevated TemperatureTube Hydroforming System for Al andMg Tubes at Elevated Temperature
This project isdivided into 2phases as follows:
Phase I: Feasibilitystudy for warm tubehydroformingprocess(COMPELTED )
Phase II: Design ofa new and practical
warm tubehydroformingsystem (INPROGRESS)
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ForgingForgingResearchResearch
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ERC/NSM Activities in ForgingERC/NSM Activities in Forging
1. Materials1. MaterialsDetermination of material flow stress data by cylinder compression tests.
2. Tribology (Friction, Tool Wear)2. Tribology (Friction, Tool Wear)Performance evaluation of cold forging lubricants.
3. Process Modeling / Tool and Process Design3. Process Modeling / Tool and Process Design• Prevention of Ductile Fracture (Chevron Cracks)• Three Dimensional Finite Element Simulation of Orbital Forming of
Spindle/Bearing Assembly
• Microforming of Medical Devices
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Compression Tooling
Samples before & after
the compression test
Materials/Flow Stress- Cylinder Compression Test -
Upper plate
Carbideinserts
Load-cell
Lower plate
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Materials/Flow Stress- Cylinder Compression Test -
K= 117 Ksi, n=0.18 determined by least square fit
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Tribology/ Double Cup ExtrusionTooling
Double cup extrusion test – Principle & Tooling
h 1
h 2
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Ring Compression Test at ElevatedTemperature
Ring Compression Test at ElevatedTemperature
Ring compression tests were conducted at elevated temperature toRing compression tests were conducted at elevated temperature todetermine the effect of temperature on lubricant performancedetermine the effect of temperature on lubricant performance
Dry (top) Lubricant (bottom)Dry (top) Lubricant (bottom)TD,BD,Ring:150TD,BD,Ring:150 °°CCSpeed: 65mm/secSpeed: 65mm/sec
ID: 18.71 mm (top), 19.98 mm (bottom)ID: 18.71 mm (top), 19.98 mm (bottom)RC3RC3
Lubricant (top & bottom)Lubricant (top & bottom)TD,BD,Ring:150TD,BD,Ring:150 °°CC
Speed: 65mm/secSpeed: 65mm/sec
ID: 19.81 mm (top & bottom)ID: 19.81 mm (top & bottom)RC2RC2
Lubricant (top & bottom)Lubricant (top & bottom)TD:150TD:150 °°CC BD, Ring: 25BD, Ring: 25 °°CCSpeed: 65mm/secSpeed: 65mm/sec
ID: 19.78 mm (top), 20.56 mm (bottom)ID: 19.78 mm (top), 20.56 mm (bottom)RC1RC1
Final Ring GeometriesFinal Ring GeometriesTest ConditionsTest Conditions
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Process Modeling/Defects in Forward Extrusion
Process Modeling/Defects in Forward Extrusion
Prediction of chevron cracking in forward extrusion
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Process Modeling/Prediction of Chevron Cracks
Process Modeling/Prediction of Chevron Cracks
Click to view animation
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Process Modeling/Orbital Forming
Process Modeling/Orbital Forming
Assembly of inner race on a forged shaft
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Process Modeling/Orbital Forming
Process Modeling/Orbital Forming
Click to view animation
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Process Modeling/Micro - Forming
Process Modeling/Micro - Forming
Microforming of cutting blades(Part thickness = 0.1 mm; flash thickness = 0.01 mm)
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Process Modeling/Micro - Forming
Process Modeling/Micro - Forming
Click to view animation
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Summary and Future Outlook Summary and Future Outlook
With the aid of experiments and FEM analysis ERC/NSM has helpedWith the aid of experiments and FEM analysis ERC/NSM has helpedachieve continuous process and product improvement in the fieldsachieve continuous process and product improvement in the fields ofofStamping, Hydroforming and Forging.Stamping, Hydroforming and Forging.
ERC/NSM has advanced experimental and computational capabilitiesERC/NSM has advanced experimental and computational capabilities forformetalforming research.metalforming research.
ERC/NSM has been and will be involved in conducting cutting edgeERC/NSM has been and will be involved in conducting cutting edgemetalforming research in association with industry and governmenmetalforming research in association with industry and governmen t.t.