Analysis of Elliptical Cup Drawing Process of SUS304 Stainless Metal

Abstract:

Article Preview

A methodology of formulating an elasto-plastic three-dimensional finite element model, which is based on Prandtl-Reuss flow rule and von Mises yield criterion respectively, associated with an updated Lagrangian formulation. An extended r-min algorithm is proposed to formulate the boundary conditions, such as the yield of element, maximum allowable strain increment, maximum allowable rotation increment, maximum allowable equivalent stress increment, and tolerance for nodes getting out of contact with tool. In order to verify the reliability and accuracy of the FEM code, the fractured thickness of a specimen in the simple tension test is adopted as the fracture criterion of forming limit in simulation. A set of tools was designed to perform the elliptical cup drawing experiment on the hydraulic forming machine. According to the simulation and experimental results, the minimum thickness is concentrated on the contact regions between work-piece and punch major axis, because the camber radius is relatively large along the minor axis, the ones that bear are relatively small to the circular tensile stress, so the thickness does not change much. The limit drawing ratio (LDR) amounts to about 2.136 for penetration in the elliptical cup drawing process of this study. According to the definition of LDR, when the die radius is increased from R3.0mm to R9.0mm, the LDR would increase from 2.11 to 2.157. When the punch radius is increased from r3.0mm to r9.0mm, the LDR would increase from 2.07 to 2.181. This paper has provided a better understanding of the elliptical cup drawing process for improving the manufacturing processes and the design of tools.

Info:

Periodical:

Advanced Materials Research (Volumes 83-86)

Edited by:

M. S. J. Hashmi, B. S. Yilbas and S. Naher

Pages:

350-357

DOI:

10.4028/www.scientific.net/AMR.83-86.350

Citation:

Y. M. Huang and Y. W. Tsai, "Analysis of Elliptical Cup Drawing Process of SUS304 Stainless Metal", Advanced Materials Research, Vols. 83-86, pp. 350-357, 2010

Online since:

December 2009

Export:

Price:

$35.00

[1] C. H. Lee, and S. Kobayashi, Elasto-plastic analysis of plane strain and axisymmetric flat punch indentation by the finite element method, International Journal of Mechanical Sciences, Vol. 12 (1970), pp.349-370.

DOI: 10.1016/0020-7403(70)90088-3

[2] R.M. McMeeking and J. R. Rice, Finite element formulations for problems of large elasticplastic deformation, International Journal of Solids and Structures, Vol. 11 (1975), p.601616.

DOI: 10.1016/0020-7683(75)90033-5

[3] R. Hill, Some basic principles in the mechanics of solids without a natural time, Journal of the Mechanics and Physics of Solids, Vol. 7 (1959), pp.209-225.

DOI: 10.1016/0022-5096(59)90007-9

[4] A. Makinouchi and M. Kawka, Process simulation in sheet metal forming, Journal of Materials Processing Technology, Vol. 46 (1994), 291-307.

DOI: 10.1016/0924-0136(94)90117-1

[5] M. Kawka and A. Makinouchi, Shell-element formulation in the static explicit FEM code for the simulation of sheet stamping, Journal of Materials Processing Technology, Vol. 50 (1995), pp.105-115.

DOI: 10.1016/0924-0136(94)01373-9

[6] A. M. Zaky, A. B. Nassr and M. G. EL-Sebaie, Optimum blank shape of cylindrical cups in deep drawing of anisotropic sheet metals, Journal of Materials Processing Technology, Vol. 76 (1998), pp.203-211.

DOI: 10.1016/s0924-0136(97)00349-x

[7] H. Huh, S. H. Kim and S. H. Kim, Process design for multi-stage elliptic cup drawing with the large aspect ratio, European Congress on Computational Methods in Applied Sciences and Engineering, (2000), pp.11-14.

[8] J. B. Kim, J. W. Yoon, D. Y. Yang and F. Barlat, Investigation into wrinkling behavior in the elliptical cup deep drawing process by finite element analysis using bifurcation-theory, Journal of Materials Processing Technology, Vol. 111 (2001).

DOI: 10.1016/s0924-0136(01)00504-0

[9] Y. M. Huang, Y. W. Tsai, and C. C. Li, Analysis of forming limits in metal forming processes, Journal of Materials Processing Technology, Vol. 201 (2008), pp.385-389.

DOI: 10.1016/j.jmatprotec.2007.11.279

[10] Y. Yamada, N. Yoshimura, and T. Sakurai, Plastic stress strain matrix and its application for the solution of elastic-plastic problem by the finite element method, International Journal of Mechanical Sciences, Vol. 10 (1968), pp.343-354.

DOI: 10.1016/0020-7403(68)90001-5

In order to see related information, you need to Login.