The stretch flanging process is significantly affected by various geometrical,material and process parameters.The punch-die clearance and initial flange length are main parameters which have major effects on the edge ...The stretch flanging process is significantly affected by various geometrical,material and process parameters.The punch-die clearance and initial flange length are main parameters which have major effects on the edge crack location and strain distribution along die profile radius in the flange.Non-axisymmetric stretch flanging process of AA-5052 sheet metal blanks was carried out by numerical simulation to predict the deformation behavior of flange,location and propagation of crack in flange and to investigate the effect of punch die clearance,flange length,die and punch profile radius and friction in the stretch flanging process.The experimental investigations were made to validate the simulations results.The results reveal that the crack length increases with the increase in the flange length.It is found that the flange length has a significant effect in circumferential direction as compared with the radial direction.The punch die clearance has the most significant effect in crack propagation in comparison with flange length.The circumferential strain is found to be larger in the case of punch having the profile radius less than the die profile radius,which leads to faster edge crack propagation.A close agreement is found between simulation and experimental results in terms of location of edge crack and forming load.展开更多
The forming mechanism of hole flanging on a thick-wall heavy cylinder forging is simulated by DEFORM3D. The cylinder is 4 390 mm in diameter and 390 mm in thickness. The results show that the compound deformation with...The forming mechanism of hole flanging on a thick-wall heavy cylinder forging is simulated by DEFORM3D. The cylinder is 4 390 mm in diameter and 390 mm in thickness. The results show that the compound deformation with bending and expanding happens in the process of hole flanging. The diameter of pre-hole of the workpiece is one of the key parameters in the process of hole flanging. The optimal diameter is obtained for reverse-conical hole of average diameter 40 mm by simulation of hole flanging process on 5 pre-holes with different diameters and 3 pre-holes with different shapes. The results can provide the scientific base for engineering application of the process.展开更多
基金the Science and Engineering Research Board(SERB)Department of Science & Technology,Government of India for financially supporting this research
文摘The stretch flanging process is significantly affected by various geometrical,material and process parameters.The punch-die clearance and initial flange length are main parameters which have major effects on the edge crack location and strain distribution along die profile radius in the flange.Non-axisymmetric stretch flanging process of AA-5052 sheet metal blanks was carried out by numerical simulation to predict the deformation behavior of flange,location and propagation of crack in flange and to investigate the effect of punch die clearance,flange length,die and punch profile radius and friction in the stretch flanging process.The experimental investigations were made to validate the simulations results.The results reveal that the crack length increases with the increase in the flange length.It is found that the flange length has a significant effect in circumferential direction as compared with the radial direction.The punch die clearance has the most significant effect in crack propagation in comparison with flange length.The circumferential strain is found to be larger in the case of punch having the profile radius less than the die profile radius,which leads to faster edge crack propagation.A close agreement is found between simulation and experimental results in terms of location of edge crack and forming load.
文摘The forming mechanism of hole flanging on a thick-wall heavy cylinder forging is simulated by DEFORM3D. The cylinder is 4 390 mm in diameter and 390 mm in thickness. The results show that the compound deformation with bending and expanding happens in the process of hole flanging. The diameter of pre-hole of the workpiece is one of the key parameters in the process of hole flanging. The optimal diameter is obtained for reverse-conical hole of average diameter 40 mm by simulation of hole flanging process on 5 pre-holes with different diameters and 3 pre-holes with different shapes. The results can provide the scientific base for engineering application of the process.
