Numerical Investigations of the Effect of Process Parameters on Residual Stresses, Strains and Quality of Final Product in Blanking Using SPH Method

Abstract:

The shearing process such as the blanking of sheet metals has been used often to prepare workpieces for subsequent forming operations. This process consists in separating a blank from a sheet by means of a high-localized shear deformation due to the action of a punch. Blanking modelling is becoming an increasingly important tool in gaining understanding and improving this process. At the moment a fundamental problem in numerical modelling of blanking processes is an excessive element distortion in a finite-element simulation. In this study, we present a hybrid modelling approach, SPH (smoothed particle hydrodynamics) coupled FEM method to simulate the blanking process. This new approach involves several advantages compared to the traditional finite element method for example: neglect mesh tangling and distortion problems, does not need to use material separation criterion. The physical, mathematical and computer model of the process is elaborated. The application in ANSYS/LS-DYNA program is developed. The examination and analysis of influence of process technological parameters for example: the clearance, tool geometry, blanking velocity on residual stresses, strains and quality of final product using the SPH method is analyzed. The results of computer simulations can be used to forecasting quality of the parts optimization.

• Periodical: Materials Science Forum (Volume 862)
• Pages: 238-245
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.862.238
• Online since: August 2016
• Authors: Łukasz Bohdal*, Agnieszka Kułakowska, Radoslaw Patyk, Marcin Kulakowski
• Keywords: Blanking Process, Numerical Analysis, Numerical Modelling, SPH Method

References

[1] L. Bohdal, L. Kukielka, K. Kukielka, A. Kulakowska, L. Malag, R. Patyk, Three Dimensional Finite Element Simulation of Sheet Metal Blanking Process, Applied Mechanics and Materials 474 (2014) 430-435.

DOI: 10.4028/www.scientific.net/amm.474.430

[2] P. Kaldunski, L. Kukielka, Numerical Analysis and Simulation of Drawpiece Forming Process by Finite Element Method, Applied Mechanics and Materials 474 (2014) 153-158.

DOI: 10.4028/www.scientific.net/amm.474.153

[3] R. Patyk, A. Kulakowska, L. Bohdal, Ekologiczne, ekonomiczne i eksploatacyjne aspekty stosowania obróbki nagniataniem (in Polish), Annual Set The Environment Protection 16 (2014) 351-362.

[4] J. Chodor, L. Kukielka, Numerical analysis of micromachining of C45 steel with single abrasive grain. GAMM 79th Annual Meeting of the International Association of Applied Mathematics and Mechanics, 31 March – 4 April, Bremen, Germany (2008).

DOI: 10.1002/pamm.200810715

[5] J. Chodor, L. Kukielka, Numerical analysis of chip formation during machining for different value of failure strain, PAMM 7 (1) (2008) 4030031-4030032.

DOI: 10.1002/pamm.200700832

[6] J. Chodor, L. Kukielka, Using Nonlinear Contact Mechanics in Process of Tool Edge Movement on Deformable Body to Analysis of Cutting and Sliding Burnishing Processes, Applied Mechanics and Materials 474 (2014) 339-344.

DOI: 10.4028/www.scientific.net/amm.474.339

[7] L. Kukielka, A. Kulakowska, R. Patyk, Numerical modeling and simulation of the movable contact tool-worpiece and application in technological processes, Journal of Systemics, Cybernetics and Informatics 8/3 (2010) 36-41.

[8] A. Kulakowska, L. Kukielka, Numerical analysis and experimental researches of burnishing rolling process with taking into account deviations in the surface asperities outline after previous treatment, Steel Research International 2 (2008) 42-48.

DOI: 10.1002/pamm.200810733

[9] A. Kulakowska, Problems of surface preparation under burnishing rolling in aspect of product quality, Steel Research International 81/9 (2010).

[10] A. Kulakowska, Experimental researches of burnishing rolling process of regular surface asperities prepared in turning process. Steel Research International 2012. Special Edition: 14th International Conference on Metal Forming, pp.127-131.

[11] A. Kulakowska, L. Kukielka, K. Kukielka, R. Patyk, L. Malag, L. Bohdal, Possibility of Steering of Product Surface Layers Properties in Burnishing Rolling Process, Applied Mechanics and Materials 474 (2014) 442-447.

DOI: 10.4028/www.scientific.net/amm.474.442

[12] A. Kulakowska, R. Patyk, L. Bohdal, Zastosowanie obróbki nagniataniem w tworzeniu ekologicznego produktu (in Polish), Annual Set The Environment Protection 16 (2014) 323-335.

[13] L. Kukielka, K. Kukielka, A. Kulakowska, R. Patyk, L. Malag, L. Bohdal, Incremental Modelling and Numerical Solution of the Contact Problem between Movable Elastic and Elastic/Visco-Plastic Bodies and Application in the Technological Processes, Applied Mechanics and Materials 474 (2014).

DOI: 10.4028/www.scientific.net/amm.474.159

[14] K. Kukielka, L. Kukielka, L. Bohdal, A. Kulakowska, L. Malag, R. Patyk, 3D Numerical Analysis the State of Elastic/Visco-Plastic Strain in the External Round Thread Rolled on Cold, Applied Mechanics and Materials 474 (2014) 436-441.

DOI: 10.4028/www.scientific.net/amm.474.436

[15] S. Faszynka, J. Lewandowski, D. Rozumek, Numerical Analysis of Stress and Strain in Specimens with Rectangular Cross-Section Subjected to Torsion and Bending with Torsion, Acta Mechanica et Automatica 10, no 1 (35)/(2016).

DOI: 10.1515/ama-2016-0001

[16] A. Bohojło-Wiśniewska, Numerical Modelling of Humid Air Flow Around a Porous Body, Acta Mechanica et Automatica 9, no 3 (33)/(2015).

DOI: 10.1515/ama-2015-0027

[17] J. Rojek, Sz. Nosewicz, K. Pietrzak, M. Chmielewski, Simulation of Powder Sintering Using a Discrete Element Model, Acta Mechanica et Automatica 7, no 3 (25)/(2013).

DOI: 10.2478/ama-2013-0030

[18] L. Bohdal, A. Kulakowska, R. Patyk, Analysis of slitting of aluminium body panels in the aspect of scrap reduction, Annual Set The Environment Protection 16 (2014) 105-114.

[19] E. Bagci, 3-D numerical analysis of orthogonal cutting process via mesh-free method, International Journal of Physical Sciences 6 (2011) 1267-1282.

[20] Y. Xi, M. Bermingham, G. Wang, M. Dargusch, SPH/FE modeling of cutting force and chip formation during thermally assisted machining of Ti6Al4V alloy, Computational Materials Science 84 (2014) 188-197.

DOI: 10.1016/j.commatsci.2013.12.018

[21] L. Bohdal, L. Kukielka, Application of variational and FEM methods to the modelling and numerical analysis of guillotining process for geometrical and physical nonlinearity, Mechanika 20(2) (2014) 197-204.

DOI: 10.5755/j01.mech.20.2.6941

[22] J. Chodor, L. Kukielka, Using Nonlinear Contact Mechanics in Process of Tool Edge Movement on Deformable Body to Analysis of Cutting and Sliding Burnishing Processes, Applied Mechanics and Materials 474 (2014) 339-344.

DOI: 10.4028/www.scientific.net/amm.474.339

[23] L. Kukielka, K. Geleta, K. Kukielka, Modelling of Initial and Boundary Problems with Geometrical and Physical Nonlinearity and its Application in Burnishing Processes, Steel Research International. Special Edition: 14th International Conference Metal Forming, 2012, pp.1375-1378.

[24] L. Malag, L. Kukielka, K. Kukielka, A. Kulakowska, L. Bohdal, R. Patyk, Problems Determining of the Mechanical Properties of Metallic Materials from the Tensile Test in the Aspect of Numerical Calculations of the Technological Processes, Applied Mechanics and Materials 474 (2014).

DOI: 10.4028/www.scientific.net/amm.474.454

[25] R. Patyk, L. Kukielka, Optimization of geometrical parameters of regular triangular asperities of surface put to smooth burnishing, Steel Research International 2 (2008) 642 - 647.

[26] R. Patyk , New method of technological surface layer shaping of machine parts during duplex burnishing rolling process. Steel Research International 2012, Special Edition: 14th International Conference on Metal Forming.

[27] R. Patyk, L. Kukielka, K. Kukielka, A. Kulakowska, L. Malag, L. Bohdal, Numerical Study of the Influence of Surface Regular Asperities Prepared in Previous Treatment by Embossing Process on the Object Surface Layer State after Burnishing, Applied Mechanics and Materials 474 (2014).

DOI: 10.4028/www.scientific.net/amm.474.448

[28] W. Ogierman, G. Kokot, Numerical analysis of the influence of the blast wave on the composite structure, Mechanika 20(2) (2014) 147-152.

[29] S. Abolfazl Zahedi, M. Demiral, A. Roy, V. Silberschmidt, FE/SPH modelling of orthogonal micro-machining of f. c. c. single crystal, Computational Materials Science 78 (2013) 104–109.

DOI: 10.1016/j.commatsci.2013.05.022

[30] RA. Gingold, JJ. Monaghan, Smooth particle hydrodynamics: theory and application to non-spherical stars, Monthly Notices of the Royal Astronomical Society 181 (1977) 375-389.

DOI: 10.1093/mnras/181.3.375

[31] R. Das, PW. Cleary, Modeling plastic deformation and thermal response in welding using smoothed particle hydrodynamics, 16th Australasian fluid mechanics conference, 2–7 December (2007).

[32] J. Domski, J. Katzer, Load-deflection characteristic of fibre concrete based on waste ceramic aggregate, Annual Set The Environment Protection 15 (2013) 213-230.

[33] M. K. Babouri, N. Ouelaa, A. Djebala, Temporal and frequential analysis of the tools wear evolution Mechanika 20(2) (2014) 205-212.

DOI: 10.5755/j01.mech.20.2.6933

[34] P. Kałduński, L. Kukiełka, Dynamic nonlinear modelling of deep drawing process on the curved line drawing die with planar anisotropy by Finite Element Method, Machine Dynamics Research 34 (1) (2010) 38-43.