Simulation of contact pressure in sheet metal trimming/blanking process

In the car body stamping process, trim/blank die cutting edges are subjected to very high tribological loads that result in loss of tool material from both the punch and die cutting edges. According to Archard’s wear model, normal contact force and sliding distance directly affects the wear. Therefore, knowledge of the acting forces on local contact areas has a pivotal role towards the prediction of tool wear. This paper presents a finite element modelling approach to determining the contact pressure distribution on the tool cutting edges during a trimming/blanking process. Characteristic areas on sheared edge profile, variation of punch force and high contact pressures affected areas have also been analysed.

Contact pressure evolution and its relation to wear in sheet metal forming

For a given sheet metal forming process, an accurate determination of the contact pressure distribution is an essential step towards the estimation of tool life. This investigation utilizes finite element (FE) analysis to model and explain the evolution and distribution of contact pressure over the die radius, throughout the duration of a channel forming process. It was found that a typical two-peak steady-state contact pressure response exists for the majority of the process. However, this was preceded by an initial transient response, characterized by extremely large and localized contact pressures, which were more than double the magnitude of the steady-state peak pressure. The validity of the predicted contact pressure behavior was assessed via detailed numerical analysis and by examining the wear response of an experimental stamping operation. The experimental results revealed that the high contact pressure zones of the transient response corresponded to a severe galling wear mechanism. Therefore, the transient response may be of primary significance to the tool wear response; thus questioning the applicability of traditional bending-under-tension wear tests for sheet metal stamping processes. Finally, a parametric study was conducted, examining the influence of the major process parameters on the steady-state and peak transient contact pressures, using the developed FE model. It was found that the bend ratio and the blank material ultimate tensile strength had the most influence on the peak contact pressures. The main process-related parameters, friction coefficient and blank holder force, were found to have only a minor influence.

Contact pressure prediction in sheet metal forming using finite element analysis

Tool wear has become a significant issue associated with the forming of high strength sheet steels in the automotive industry. In order to combat this problem, recent research has been devoted to utilizing the contact results obtained from current sheet metal forming software predictions, in order to develop/apply tool wear models or tool material selection criteria for use in the stamping plant. This investigation aims to determine whether a specialized sheet metal forming software package can correctly capture the complex contact conditions that occur during a typical sheet metal stamping process. The contact pressure at the die radius was compared to results obtained using a general-purpose finite element software package, for a simple channel-forming process. Although some qualitative similarities between the two predictions were observed, it was found that significant differences in the magnitude and distribution of the contact pressure exists. The reasons for the discrepancies in results are discussed with respect to the simplifications and assumptions adopted in the finite element model definitions, and with regards to other results available in the literature.

FEA simulation of contact and wear between non-metallic materials for accelerated new product development

The conventional approach ie laboratory life testing to examine the reliability of products takes long time and involves tremendous cost as samples are tested till failures. The accelerated life test (ALT) has recently been used as an alternative method. Although ALT reduces the cost of reliability testing through applying more severe environmental conditions than the normal ones, it is no longer sufficient as it does not describe the process of products’ failure explicitly and it is still highly dependent on physical testing. Consequently, novel practices need to be developed for better understanding of the products’ reliability. A novel Finite Element Analysis (FEA) model incorporating mathematical wear equations is developed in the current work and applied to polymer materials. Wear rate, a key parameter, is calculated by using a combinatorial formula that combines a conventional linear equation with a recently published exponential equation. The local wear is firstly calculated and then integrated over the sliding distance. The FEA simulation works in a loop and performs a series of simulation with updated surface geometries. The simulation is in good agreement with the physical testing result.

Contact pressure evolution at the die radius in sheet metal stamping

The contact conditions at the die radius are of primary importance to the wear response for many sheet metal forming processes. In particular, a detailed understanding of the contact pressure at the wearing interface is essential for the application of representative wear tests, the use of wear resistant materials and coatings, the development of suitable wear models, and for the ultimate goal of predicting tool life. However, there is a lack of information concerning the time-dependant nature of the contact pressure response in sheet metal stamping. This work provides a qualitative description of the evolution and distribution of contact pressure at the die radius for a typical channel forming process. Through an analysis of the deformation conditions, contact phenomena and underlying mechanics, it was identified that three distinct phases exist. Significantly, the initial and intermediate stages resulted in severe and localised contact conditions, with contact pressures significantly greater than the blank material yield strength. The final phase corresponds to a larger contact area, with steady and smaller contact pressures. The proposed contact pressure behaviour was compared to other results available in the literature and also discussed with respect to tool wear.

A post-contact Aboriginal mortuary tree from southwestern Victoria, Australia

Here we document the investigation of the first Australian Aboriginal mortuary tree found since the early 20th century and the first studied by archaeologists and Aboriginal traditional owners. In 2001, a landowner discovered Aboriginal skeletal remains inside a fallen, dead tree while evaluating the tree’s potential as firewood, leading to the investigation of the site. The tree was located near Moyston, in southwestern Victoria, in traditional Djab Wurrung country and held the partial skeletons of three Aboriginal individuals—two adults and a child. Clay pipe-stem wear on several teeth belonging to the two adults indicates that these remains were broadly contemporaneous secondary placements from the early post-contact period (ca. A.D. 1835–1845). Along with five additional mortuary trees within 30 km of the Moyston tree, this practice constitutes a previously unknown traditional mortuary pattern and contributes to our understanding of the complex mortuary behavior of the Aboriginal people of southwestern Victoria.

History of contact and change in the Goroka Valley, Central Highlands of New Guinea, 1934-1949

The thesis traces the interaction of the Goroka Valley people with European and coastal New Guinean intruders during the pacification stage of contact and change. In this 15 year period the people moved from a traditional subsistence culture to the threshold of a modern, European-influenced technological society. The contact experiences of the inhabitants of the Valley and the outsiders who influenced them are examined, using both oral and documentary sources. A central theme of this study is the attempts by Europeans and their coastal New Guinean collaborators to achieve the pacification of a people for whom warfare has been described as 'the dominant orientation'. The newcomers saw pacification as being inextricably linked with social, economic and religious transformation, and consequently it was pursued by patrol officers, missionaries and soldiers alike. Following an introductory chapter outlining the pre-contact and early-contact history of the Goroka Valley people, there is a discussion of the causes of tribal fighting in Highlands communities and two case studies of violent events which, although occurring beyond the Goroka Valley, had important consequences for those who lived within its bounds. The focus then shifts to the first permanent settlement of the agents of change -initially these were coastal New Guinean evangelists and policemen - and their impact on the local people. A period of consolidation is then described, as both government and missions established a permanent 'European presence in the Valley'. This period was characterised by vigorous pacification coupled with the introduction of innovations in health and education, agriculture, technology, law and religion. The gradual transformation of Goroka Valley society as a result of the people's interaction with the newcomers was abruptly accelerated in 1943, when many hundreds of Allied soldiers occupied the Valley in anticipation of a threatened Japanese invasion. Village life was disrupted as men were conscripted as carriers and labourers and whole communities were obliged to grow food to assist the Allied war effort. Those living close to military airfields-and camps were subject to Japanese aerial attacks and the entire population was exposed to an epidemic of bacillary dysentery introduced by the combatants. However the War also brought some positive effects, including paradoxically, the almost total cessation of tribal fighting, the construction of an ail-weather airstrip at Goroka which ensured its future as a town and administrative and commercial centre, and the compulsory growing of vegetables, coffee, etc, which laid the foundations for a cash economy and material prosperity. The final chapter examines the aftermath of military occupation, the return of civil administration and the implementation of social and economic policies which brought the Goroka Valley people into the rapid-development phase of contact. By 1949 Gorokans were ready to channel their aggressive energies into commercial competitiveness and adopt a cash-crop economy, to accept the European rule of law, to take advantage of Western innovations in medicine, education, transport and communications, to seek employment opportunities at home and in other parts of the country and to modify their primal world view with European religious and secular values. A Stone Age people was in process of being transformed into a modern society.

Photography towards painting : the techniques of large contact negatives

Investigates the relationship between painting and photography, with a special focus on techniques using large contact negatives and digital applications. The thesis is comprised of a written exegesis that contextualises and informs upon an exhibition of photographic and digital inkjet montages. It discusses the theoretical and structural issues underpinning the conceptual basis of the research and elaborates upon the applications and processes involved in producing each exhibited image.

Determinants of time-to-contact judgements

The experiments reported in this thesis investigated the visual information used by observers to judge the time-to-contact (TTC) of approaching objects. The results provide support for the proposition that TTC judgements are based on retinal image expansion rate and observers' prior experience with the objects.

Contact with nature and children's mental, emotional, and social health

This research investigated the benefits of children's contact with nature as perceived by adult educators. It was found that contact with nature is perceived to: increase self-confidence and self-esteem; provide opportunities to experience mystery, privacy, and sensory engagement; connect children with school; and accommodate different learning styles and abilities.