Prediction and Control of Both Wrinkle Limit and Fracture Limit on Cylindrical Cup Deep-Drawing

hased on both the wrinkle model and fracturc model, the wrinkle critical tangent pressure and the fractureon critical radial tensile stress are calculated respectively. The maximum tangent pressure formula in the flange deformation zone and the maximum radial tensile stress formula in the cylinder-wall pass force zone are given, and both theno-wrinkle limitl criterion and no-fracture limit criterion are put froward. The prediction and control criterion anddiagram of both the wrinkle limit and fracture limit on cylindrical cup deep-drawing, the most suitable formingzone and the limit deep-drawing coefficient are obtained. Comparing with present experience formulae and actualproduct's production, this prediction and control are quite accurate.

GENERAL COMPUTER MODEL FOR SHEET METAL DEEP-DRAWING PROCESS

A new comprehensive computer model was developed for sheet metal deep-drawing process, based on the theory of plastic anisotropy and under consideration of the effects of bending, blank-holding force, strain-hardening, the variation of thickness and tooling geometry. The model could be used to simulate the deforming stages of deep-drawing process and get the continuous distributions of stress and strain from the radial drawing region of material over a die and the stretch-forming region of material over a punch. It is concluded that the total strain theory can be used as a substitute for the incremental strain theory to analyse the force and deformation in sheet metal deep-drawing process. In addition, the effect of bending was also obtained.

Prediction and Control of both Wrinkle Limit and Fracture Limiton Cylindrical Cup Deep-drawing(Ⅱ)

The prediction and control criterion of both the wrinkle limit and fracture limit on the cylindrical cup deep-drawing are given, and the prediction and control diagram of both the wrinkle limit and fracture limit are also given. The results show that it is suitable for no-flange cylindrical cup deep-drawing, narrow-flange cylindrical cup deep-drawing, wide-flange cylindrical cup deep-drawing/expanding compound forming and rigid punch expanding forming.

FLANGE EARING AND ITS CONTROL ON DEEP-DRAWING OF ANISOTROPY CIRCULAR SHEETS

The Hill's quadric anisotropy yield function and the Barlat-Lian anisotropy yield func- tion describing well anisotropy sheet metal with stronger texture are introduced into a quadric-flow cor- ner constitutive theory of elastic-plastic finite deformation suitable for deformation localization analy- sis.And then,the elastic-plastic large deformation finite element formulation based on the virtual power principle and the discrete Kirchhoff shell element model including the yield functions and the constitutive theory are established.The focus of the present research is on the numerical simulation of the flange earing of the deep-drawing of anisotropy circular sheets,based on the investigated results, the.schemes for controlling the flange earing are proposed.

DEEP-DRAWING PROCESS ANALYSIS OF ELLIPTIC CUPS BY RIGID-PLASTIC FEM

ＤＥＥＰ－ＤＲＡＷＩＮＧＰＲＯＣＥＳＳＡＮＡＬＹＳＩＳＯＦＥＬＬＩＰＴＩＣＣＵＰＳＢＹＲＩＧＩＤ－ＰＬＡＳＴＩＣＦＥＭＤＥＥＰ－ＤＲＡＷＩＮＧＰＲＯＣＥＳＳＡＮＡＬＹＳＩＳＯＦＥＬＬＩＰＴＩＣＣＵＰＳＢＹＲＩＧＩＤ－ＰＬＡＳＴＩＣＦＥＭ￥Ｃｈａｎｇ，...

Simulation of annealing process effect on texture evolution of deep-drawing sheet Stl5

A two-dimensional cellular automaton method was used to simulate grain growth during the recrystallization annealing of deep-drawing sheet St 15, taking the simulated result of recrystallization and the experimental result of the annealing texture of deepdrawing sheet St15 as the initial condition and reference. By means of computer simulation, the microstructures and textures of different periods of grain growth were predicted. It is achieved that the grain size, shape and texture become stable after the grain growth at a constant temperature of 700℃ for 10 h, and the advantaged texture components { 111 } 〈 110 〉 and { 111 } 〈 112〉 are dominant.

Prediction and determination of both friction coefficient and forming force on sheet metal deep-drawing

On the basis of the criterion of no-wrinkle, the principle and method of prediction and determination of both friction coefficient and forming force on sheet metal deep-drawing are put forward, and proved it's expedience and practicability. They are suitable for assessment of lubricant properties. Friction coefficient and forming force are a function of material parameter, design parameter and process parameter, especially relative prevent wrinkle blank-holder force. Product of both friction coefficient and prevent wrinkle blank-holder force is only function of process parameter after determining material parameter and design parameter.

Formability improvement and blank shape definition for deep drawing of cylindrical cup with complex curve profile from SPCC sheets using FEM

In the current work, to predict and improve the formability of deep drawing process for steel plate cold rolled commercial grade （SPCC） sheets, three parameters including the blanking force, the die and punch comer radius were considered. The experimental plan according to Taguchi＇s orthogonal array was coupled with the finite element method （FEM） simulations. Firstly, the data from the test of stress-strain and forming limit curves were used as input into ABAQUS/Explicit finite element code to predict the failure occurrence of deep drawing process. The three parameters were then validated to establish their effects on the press formability. The optimum case found via simulation was finally confirmed through an experiment. In order to obtain the complex curve profile of cup shape after deep drawing, the anisotropic behavior of earring phenomenon was modeled and implemented into FEM. After such phenomenon was correctly predicted, an error metric compared with design curve was then measured.

Study on Theory and Application of the Energy Method used for Analyzing Compressive Instability in Sheet Forming

It is pointed out that there was serious weakness w he n using the energy method for studying compressive plastic instability in sheet forming in the past. Where applying the deduced instability strengths to relativ e engineering analysis, theoretical solutions were away from practices. Its basi c reason is that simplified process in mathematical analysis of elastic bending energy was completely applied to that of plastic bending energy. Where the cambe r expressed by function of displacement normal to a plate was approximated to re alistic deflective camber, the displacement of deflected plate to compressed dir ection was neglected. With the aid of the improved instability strengths, the pr edictions on both critical buckling dimension of blank in cup deep-drawing with out blankholder through cylindrical die or conical die and the minimum blankhold er pressure to prevent buckling under constant load are universally in agreement with both experimental results and experiential data. On the bases of above-mentioned improvement, the approximate expressions for bo th the curvature and the twist used in equation of the energy of elastic bending are also ameliorated. Thus the obtained general equations for both the energy a nd the work done by internal force in plastic bending of a plate are more precis e than before. In the analyses of plastic buckling of shell with bending moment, the effect of bending moment is considered through the work done by simulative bending for ce. The method proposed in this paper can not only simplify analyses but also ge t practical result.

Quantitative Evaluation for Drawability of Sheet Metal

The theoretical evaluating method is given for the drawability of the sheet with normal anisotropy. The general solution on the cracking load of deep-drawing is deduced, which is based on three kinds of hardening curve of materials most in use. The distributions of stress and strain in the deformed region and the drawing force are obtained by the numerical method. The limiting drawing ratio is calculated through computer-aided simulating test. The experiments of deep-drawing to four kinds of sheet metals express that the relative errors between the predictive and the experimental results about the cracking load and the limiting drawing ratio are within 5%. The drawability of common sheet metals can be quantitatively evaluated in precise terms by means of the theory and the method advanced in this paper.

Stress-strain analysis on AA7075 cylindrical parts during hot granule medium pressure forming

Hot granule medium pressure forming(HGMF) is a technology in which heat-resistant granules are used to replace liquids or gases in existing flexible-die forming technology as pressure-transfer medium. Considering the characteristic of granule medium that seals and loads easily, the technology provides a new method to realize the hot deep-drawing forming on high strength aluminum alloy sheet. Based on the pressure-transfer performance test of granule medium and the material performance test of AA7075-T6 sheet, plastic mechanics analysis is conducted for the areas, such as the flange area, force-transfer area and free deforming area, of cylindrical parts deep-drawn by HGMF technology, and the function relation of forming pressure is obtained under the condition of nonuniform distribution of internal pressure. The comparison between theoretical result and experimental data shows that larger deviation occurs in the middle and later period of forming process, and the maximum theoretical forming force is less than the experimental value by 24.6%. The variation tendency of the theoretical thickness curve is close to the practical situation, and the theoretical value basically agrees well with experimental value in the flange area and the top area of spherical cap which is in the free deforming area.

Instability analysis of free deformation zone of cylindrical parts based on hot-granule medium-pressure forming technology

The cylindrical part of sheet metal based on hot-granule medium-pressure forming (HGMF) technology was investigated.The stress functions of the free deformation zone and the fracture instability theory were combined to establish the analytical expression of the critical pressure of punch. The results show that the active friction between the granule medium and the sheet metal, as well as the non-uniform internal pressure presented by the solid granule medium, can obviously improve the forming performance of the sheet metal. The critical pressure of punch increases with the increment of the friction coefficient between the granule medium and sheet metal, as well as the plastic strain ratio, whereas it decreases with the increase of the material-hardening exponent. Furthermore, the impact on the critical pressure from high to low order is the plastic strain ratio, the friction coefficient,and material-hardening exponent. The deep-drawing experiment with HGMF technology on AZ31B magnesium alloy sheet verified the instability theory.Key words: hot-granule

Effect of preforming on the formability of TRIP steel sheet forming processes

In this study,the formability of transformation-induced plasticity (TRIP) steel is studied during deep-drawing processes with preforming.The effects of preforming on theminimum thickness of can are investigated with a constitutive model accompanying strain-induced martensite transformation in prestrain condition.The constitutive model has been implemented into ABAQUS/UMAT for analysis of TRIP steel-forming processes.The results show that preforming slightly influences the thickness uniformity of TRIP steel in forming.

INFLUENCE OF STRESS STATE ON EARING BEHAVIOR──（Ⅰ） CRYSTALLOGRAPHIC ANALYSIS OF FCC METALS

ＩＮＦＬＵＥＮＣＥＯＦＳＴＲＥＳＳＳＴＡＴＥＯＮＥＡＲＩＮＧＢＥＨＡＶＩＯＲ──（Ⅰ）ＣＲＹＳＴＡＬＬＯＧＲＡＰＨＩＣＡＮＡＬＹＳＩＳＯＦＦＣＣＭＥＴＡＬＳ￥ＬｉＳａｉｙｉ；ＺｈａｎｇＸｉｎｍｉｎｇ；ＬｉＬｕｏｘｉｎｇ（ＤｅｐａｒｔｍｅｎｔｏｆＭａｔ...

Strain Capacities Limits of Wrought Magnesium Alloys: Tension vs. Expansion

Lightening structure is one of the goals of many fields of research. As a result, magnesium alloys are studied due to their low density. However, one drawback of these alloys is their low formability at room temperature due to their hexagonal closed-packed structure. In the present work, the forming capacity of an AZ31 Mg alloys has been studied using a mini deep-drawing device, image correlation techniques and tests (tension and expansion) at temperatures contained between 20°C and 200°C. To investigate formability limits of Mg alloys in expansion, major and minor strains data were generated using hemispherical punch tests and analyzed with 3D digital images correlation techniques. Thanks to images correlation, strains on the surface of the samples were observed by means of a double digitization of the sample in three dimensions before and after deformation by using stereoscopic vision and triangulation. Image correlations have also been used in 2D to measure strains on the surface of the tensile test samples. These tests gave interesting information on the evolution of various parameters such as hardening coefficient, strain rate sensitivity parameter, and Lankford coefficient, which may affect the behavior of the alloys. Finally, the forming limits in both configurations (tension and expansion) were compared and discussed.

Great progress in developing 500 MHz single cell superconducting cavity in China

Superconducting cavities have been adopted in many kinds of accelerator facilities such as synchrotron radiation light source, hard X-ray free electron laser linac, colliders and energy recovery linacs (ERL). The 500 MHz superconducting cavities will be a candidate to be installed in the high current accelerators and high current ERLs for their large beam aperture, low higher order modes impedance and high current threshold value. This paper presents great progress in the whole sequence of developing 500 MHz superconducting cavity in China. It describes the first in-house successful development of 500 MHz single cell superconducting cavity including the deep-drawing of niobium half cells, electron beam wielding of cavity, surface preparations and vertical testing. The highest accelerating gradient of the fabricated cavity #SCD-02 higher than 10 MV/m was obtained while the quality factor was better than 4×108 at 4.2 K, which has reached the world level of the same kind of cavities.