Study of Forming Behaviour of Square Hole Mild Steel Perforated Sheet Metal

Abstract:

As the study of formability of perforated sheet metals using conventional approach is exhaustive and time consuming, Finite Element Analysis is used to carry out the same. This paper attempts to study the effects of perforation parameters (viz. hole size, open area and thickness) on the formability of square hole Perforated Mild Steel Sheet Metal. Finite element analysis is done using commercial Finite Element Analysis software LS-DYNA. Parametric analysis is carried out to optimize process parameters using Taguchi’s L9 orthogonal array. From the results obtained through simulation, the analysis of variance (ANOVA) is carried out to determine which group has best condition for drawing and regression equation is obtained to know, how a single response variable (Major or Minor strain) is related to a variety of predictor variables (percentage open area, hole size and thickness) and the graphs are plotted between them using MINITAB software.

• Periodical: Applied Mechanics and Materials (Volume 852)
• Pages: 218-228
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.852.218
• Online since: September 2016
• Authors: G. Venkatachalam*, J. Nishanth, M. Mukesh, D.S. Pavan Kumar
• Keywords: ANOVA, Blank Thickness, Finite Element Analysis (FEA), FLD, Hole Size, Ligament Ratio, Open Area

References

[1] Keeler S.P. and Backofen W.A., Plastic Instability and Fracture in Sheets Stretched Over Rigid Punches, Transactions of The ASM (1963), Vol. 56, 25-48.

[2] Goodwin, G.M., Application of Strain Analysis to Sheet Metal Forming Problems in the Press Shop, Society of Automotive Engineers, Technical Paper no. 680093 (1968).

DOI: 10.4271/680093

[3] Hill, R., On Discontinuous Plastic States, With Special Reference to Localized Necking in Thin sheets, Journal of the Mechanics and Physics of Solids (1952), Vol. 1, pp.19-30.

DOI: 10.1016/0022-5096(52)90003-3

[4] Marciniak, Z. and Kuczynski, K., Limits Strains in The Processes of Stretch-Forming Sheet Metal, International Journal of Mechanical Sciences (1967). Vol. 9, pp.609-620.

DOI: 10.1016/0020-7403(67)90066-5

[5] Hutchinson, J.W. and Neale, K.W. Sheet Necking-III. Strain-Rate Effects, in Mechanics of Sheet Metal Forming, eds. D.P. Koistinen and N.M. Wang Plenum. New York (1978), pp.269-283.

DOI: 10.1007/978-1-4613-2880-3_11

[6] Hill, R. A Theory of The Yielding And Plastic Flow of Anisotropic Materials. Proceedings of Royal society of London (1948), A193, pp.281-97.

[7] Painter M.J. and Pearce R., Instability and Fracture in Sheet Metal, Journal of Physics D: Applied Physics (1974), Vol. 7, pp.992-1002.

DOI: 10.1088/0022-3727/7/7/307

[8] G. Venkatachalam, S. Narayanan, C. Sathiya Narayanan and R. Abhishek: Journal of Manufacturing Engineering (2011), Vol. 6, pp.1-4.

[9] Venkatachalam, G., Narayanan, S., Sathiya Narayanan, C. and Abhishek, R., Analysis of Perforated Sheet Metals with Square and Hexagonal Holes Using Finite Element Method, Journal of Manufacturing Engineering (2011), Vol. 6, pp.1-4.

[10] Venkatachalam, G., Narayanan, S. and Sathiya Narayanan, C., Prediction of Limiting Strains for Square pattern – Square Hole Perforated Commercial Pure Aluminium Sheets, Advanced Materials Research (2012), Vol. 548, pp.382-386.

DOI: 10.4028/www.scientific.net/amr.548.382

[11] F.K. Chen: Journal of Materials Processing Technology (1993), Vol. 37, p.175–188.

[12] S.C. Baik, K.H. Oh and D.N. Lee: Scripta Metallurgica et Materialia (1995), Vol. 33 (8), p.1201–1207.

DOI: 10.1016/0956-716x(95)00349-z

[13] S.C. Baik, H.N. Han, S.H. Lee, K.H. Oh and D.N. Lee: International Journal of Mechanical Sciences (1997), Vol. 39 (7), p.781–793.

[14] S.C. Baik, H.N. Han, S.H. Lee, K.H. Oh and D.N. Lee: International Journal of Mechanical Sciences, Vol. 42, (2000), p.523–536.

[15] Y.C. Lee and F.K. Chen: Journal of Materials Processing Technology, vol. 103, (2000), p.353–361.

[16] Galbraith, P. C., and Hallquist, J. O., 1995, Shell-Element Formulations in LSDYNA3D: Their Use in the Modelling of Sheet-Metal Forming, Journal of Material Processing and Technology. Vol. 50, p.158–167.

DOI: 10.1016/0924-0136(94)01377-d

[17] Yoshida, T., Katayama, T., and Usuda, U., Forming-Limit Analysis of Hemispherical-Punch Stretching Using the Three-Dimensional Finite-Element Method, Journal of Material Processing and Technology (1995), Vol. 50, p.226–237.

DOI: 10.1016/0924-0136(94)01383-c