Papers by Keyword: Stamping

Abstract: Hybrid twins and residual-learning strategies are increasingly used to reconcile the broad coverage of physics-based simulations with the fidelity of production measurements. In industrial stamping, however, truly matched simulation-experiment cases are scarce, while large-scale monitoring data are clustered around a narrow operating window. This work proposes an industrially practical hybrid metamodel in which the discrepancy (ignorance) model is trained exclusively from approximate residuals computed at in-domain production inputs, considering a surrogate of a thermal enabled AutoForm Sigma Design of Experiments (DoE). To prevent uncontrolled extrapolation, learning and evaluation are restricted to an explicitly validated domain defined through multivariate kNN support in standardized space derived from the DoE cloud. The residual model is selected through five-fold cross-validation on 10,446 in-domain production samples and then retrained on the full approximate-residual set. A small set of five matched cases is kept as an external check based on true residuals. The resulting hybrid predictor enables the generation of synthetic, experiment-informed corrected data while retaining the DoE coverage required for downstream modelling tasks.

Abstract: Achieving high geometric accuracy is crucial in stamping and bending processes. Key influencing factors include the position of the blank within the coiled sheet, leveling, strip lubrication, contour cutting, and the sequence of bending. Currently, process design and parameter selection rely largely on the expertise of experienced engineers. To enable a data-driven approach, the exact effects and interactions of process parameters must be analyzed using combinations of settings, machine data, and measurements of all manufactured parts. This study presents variance, interaction, and quality analyses based on long-term production trials for busbars. Process parameters were combined according to a statistical experimental design. The results indicate positive effects from slight pre-bending of sheet strips, active leveling, material removal through contour cutting, and simultaneous bending operations.

Abstract: The quality of a part produced using stamping process is dependent on many parameters such as the geometries of the tools and the initial blank, their surface state, the clamping force or contact pressure, the tools velocity and the lubrication. In order to discriminate different lubricants for stamping process in automotive industry under various conditions of clamping force and punch velocity, the Swift cup drawing test is used to evaluate the performance of three lubricants, i.e., two oil-based liquids and one dry film, applied on AA5182-O sheets. Moreover, finite element simulations are used to estimate friction coefficients of these lubricants.

Abstract: This paper describes the experimental study and modeling of the process of cross wedge rolling workpiece for the stamping of the crankshaft using a tool printed on a 3D printer. The study shows the design and printing features of the tool for cross wedge rolling. A comparison of the experiment and simulation in Qform program.

Abstract: In recent years, the oil and gas industries have been developing significantly. In this regard, there was a great need for the construction of main pipelines, which consist of pipes and connecting parts. The production of connecting parts of pipeline has not been studied enough to date. This article describes the process of stamping halves of stamped-welded elbows. During the stamping operation, the workpiece wall is thinned. The process of modeling this operation in a software of modeling by finite element method Deform-3D is described. The place of the greatest thinning of the wall was determined with the help of Deform-3D. The results of modeling and experimental production coincided. The main factors that may influence the degree of thinning were identified. Experimental calculations were performed in Deform-3D with a variation of these factors. As a result of the experiments carried out, the most significant factor was determined and an option was proposed to solve the problem of wall thinning. Solving this problem will help reduce the cost of production by 1.5 times.

Abstract: Bipolar plate is the key component of proton exchange membrane fuel cells. Due to the factors of rapid and mass production, the stamping process is selected to manufacture the bipolar metal plates. First, the stress-strain curve is performed by universal material testing machine.The stress-strain curve is necessary for bipolar plate stamping simultion. The maximum forging load and effective stress distribution of bipolar plate stamping are determined by finite element analysis. Finally, the effect of the traditional crank stamping on the flatness and section thickness of stainless steel bipolar plate are observed by experiments.

Abstract: The sequence and development the impulse stamping goals and production objectives are described. A new idea development from a primitive “field” technology to modern integrated technologies that allow obtaining unique quality indicators of manufactured parts is shown. The article covers the description of pulse technologies for sheet stamping by the blasting agents explosion and an underwater high-voltage discharge.

Abstract: Single point incremental forming is a major process in a number of different industrial applications. Blank are easily found around us from furniture and household equipment to industrial machinery and equipment. To ensure high-quality sheet metal, it is vital to consider the influence of parameters. Accordingly, in this paper, the parameters affecting product quality are analyzed. Through the testing process, we obtain the parameters that help the product achieve high quality in terms of mechanics, which is an important first step for the process of developing the technology.

Abstract: This paper reports the investigation of the effect of a plate dynamic loading scheme upon bimetal joint formation at explosion welding with simultaneous stamping. The investigation results of the effect of technological parameters and matrix material upon a radial deformation and quality of explosive pressed аrmco iron+steel 3 bimetal are shown. It is determined experimentally, that additional punching in modes common for explosion welding, without their intensification, allow achieving considerable deformations and manufacturing qualitative bimetal blanks with a high factor of a part form.

Abstract: Investigations of the rheological properties and the formation of the structure of stainless steel were performed. A computer model of the process of hammer forging of the turbine blades made of stainless steel 1.3 m long in the package Deform-3D was developed , with the help of which the necessary coefficients and parameters are determined to ensure maximum convergence of the calculated and experimental process data. The obtained data were used to create a mathematical model for stamping a large-sized turbine blade made of stainless steel with a length of 2.1 m. Mathematical modeling of the processes of stamping and distorting of a large-sized blade in the software package Deform-3D has been performed. The influence of process parameters on the stress-strain state (SSS), forming, temperature field in the forging at various stages of stamping. Determined temperature and deformation modes of stamping, the need for additional heating and optimal forgings geometry by stamping.