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 and wear in sheet metal forming - an FEM analysis

Wear is the principal cause of tool failure in most sheet metal forming processes. It is well known that the contact pressure between the blank and the tool has a large influence on the wear of the tool, and hence the tool life. This investigation utilises the finite element method to analyse the contact pressure distribution over the die radius for a particular deep drawing process. Furthermore, the evolution of the predicted contact pressure distribution throughout the entire stroke of the punch is also examined. It was found that the majority of the process shows a steady state pressure distribution, with two characteristic peaks over the die radius, at the beginning and end of the sheet contact area. Interestingly, the initial transient contact pressure response showed extremely high localised peak pressures; more than twice that of the steady state peaks. Results are compared to wear reported in the literature, during similar experimental deep drawing processes. Finally, the significance and effect of the results on wear and wear-testing techniques are discussed.

Modeling of contact pressure in sheet metal forming

For a given sheet metal forming process, an accurate determination of the contact pressure distribution experienced is an essential step towards the estimation of tool life. This investigation utilizes finite element (FE) analysis to determine 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 a transient  response, which produced extremely large and localized contact pressures. Notably, it was found that the peak transient contact pressure was more than double the steady-state peak. These contact pressure results may have a significant influence on the tool wear response and therefore impact current wear testing and prediction techniques. Hence, an investigation into the validity of the predicted contact pressure was conducted.

Self-representations of international women postgraduate students in the global university 'Contact Zone'

This article explores some aspects of the role of race and gender in shaping women postgraduate students' experience of intercultural study. It focuses on various social and cultural aspects of their sojourn. These were suggested by data from two small pilot research projects investigating the experiences of two cohorts of international women postgraduate students, the one studying in an Australian university and the other, a Canadian. The authors focus particularly on the intersections between the students' representation of themselves as women and the way they see themselves represented by their host cultures. In other words, they are interested in the students' understandings of themselves as 'other', and how this impacts on their representations of 'self'. The authors suggest that these representations reflect a process of negotiation of identity that occurs in what they call the globalising university 'contact zone'. The concept of contact zones derives from post-colonial theory. A further goal of this article, then, is to examine how such data appear when viewed from a post-colonial perspective.

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.

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.

Sliding distance, contact pressure and wear in sheet metal stamping

This paper directly examines the contact sliding distance experienced during a typical sheet metal stamping process-an area that has largely been neglected in the literature. A method to numerically quantify the sliding distance is proposed. The sliding distance predicted from this method, and the contact pressure obtained from numerical simulation, allow the recently identified time-dependent contact conditions on the die and blank surfaces to be completely characterized. Consequently, a new insight into the wear/galling that occurs at the die radius in sheet metal stamping is gained. The results show that the region close to zero degrees on the die radius is likely to experience the most wear, with the identified transient stage contributing to a large proportion of the total wear. Additionally, the region on the blank surface often observed to be heavily burnished - the die impact line - is estimated to experience the highest wear severity due to the transient contact conditions. The proposed method to numerically quantify the sliding contact conditions can be applied as a general approach to study any other two-body sliding contact situations.

Analytical solutions and finite element modelling of deep drawing process for cylindrical metal cups

Analytical modelling of deep drawing process is of value in preliminary process design to illustrate the influence of major variables including friction and strain hardening on punch loads, cup dimensions and process limits. In this study, analytical models including theoretical solution and a series of finite element models are developed to account for the influences of process parameters including friction coefficient, tooling geometry and material properties on deep drawing of metal cups. The accuracy of both the theoretical and finite element solutions is satisfactory compared with those from experimental work.

Individual variation of in-air female ‘pup contact’ calls in Weddell seals, Leptonychotes weddellii

Vocal recognition may function as a critical factor in maintaining the phocid mother-pup bond during lactation. For vocal recognition to function, the caller must produce individually distinct calls that are recognised by their intended recipient. Mother-pup vocal recognition has been studied extensively in colonial otariids and appears to be characteristic of this family. Although less numerous, empirical studies of phocid species have revealed a range of recognition abilities. This study investigated whether Weddell seal (Leptonychotes weddellii) females produce individually distinct 'pup contact' calls that function during natural pair reunions. Fifteen calls from each of nine females recorded in the Vestfold Hills, Antarctica were analysed. One temporal, nine fundamental frequency and five spectral characteristics were measured. Results of the cross-validated Discriminant Function Analysis revealed that mothers produce individually distinct calls with 56% of calls assigned to the correct individual. The probability of achieving this level of discrimination on novel data by chance alone is highly improbable. Analysis of eight mother-pup reunions recorded near McMurdo Sound, Antarctica further demonstrated that these 'pup contact' calls function during natural pair reunions. Behavioural analysis also revealed that pups were chiefly responsible for establishing and maintaining close contact throughout the reunion process. Our study therefore demonstrates that Weddell seal females produce calls with sufficient stereotypy to allow pups to identify them during pair reunions, providing evidence of a functioning mother-pup vocal recognition system.

Functional analysis of the leading malaria vaccine candidate AMA-1 reveals an essential role for the cytoplasmic domain in the invasion process

A key process in the lifecycle of the malaria parasite Plasmodium falciparum is the fast invasion of human erythrocytes. Entry into the host cell requires the apical membrane antigen 1 (AMA-1), a type I transmembrane protein located in the micronemes of the merozoite. Although AMA-1 is evolving into the leading blood-stage malaria vaccine candidate, its precise role in invasion is still unclear. We investigate AMA-1 function using live video microscopy in the absence and presence of an AMA-1 inhibitory peptide. This data reveals a crucial function of AMA-1 during the primary contact period upstream of the entry process at around the time of moving junction formation. We generate a Plasmodium falciparum cell line that expresses a functional GFP-tagged AMA-1. This allows the visualization of the dynamics of AMA-1 in live parasites. We functionally validate the ectopically expressed AMA-1 by establishing a complementation assay based on strain-specific inhibition. This method provides the basis for the functional analysis of essential genes that are refractory to any genetic manipulation. Using the complementation assay, we show that the cytoplasmic domain of AMA-1 is not required for correct trafficking and surface translocation but is essential for AMA-1 function. Although this function can be mimicked by the highly conserved cytoplasmic domains of P. vivax and P. berghei, the exchange with the heterologous domain of the microneme protein EBA-175 or the rhoptry protein Rh2b leads to a loss of function. We identify several residues in the cytoplasmic tail that are essential for AMA-1 function. We validate this data using additional transgenic parasite lines expressing AMA-1 mutants with TY1 epitopes. We show that the cytoplasmic domain of AMA-1 is phosphorylated. Mutational analysis suggests an important role for the phosphorylation in the invasion process, which might translate into novel therapeutic strategies.

Understanding temperature and contact pressure in hot stamped channels

This paper investigates the temperature and contact pressure conditions in hot stamped channels of boron steel. Hot stamping has been used for many years to produce high strength structural auto-motive components. The high tensile strengths achievable by hot stamping is beneficial where the intrusion during a vehicle crash is not desirable – e.g. for the vehicle occupant compartment. How-ever, the high blank temperatures and high temperature cycling causes a large amount of wear in the tooling. These conditions have led to high tool failures and die maintenance costs. Thus, un-derstanding the main causes of wear behaviour in the hot stamping process is of high interest to hot stampers.
To this aim, a generic 2D thermo-mechanical finite element model of a hat-shaped crash formed hot stamped component was developed (based on the authors previous hot stamp model), and a modified phase transformation model based on Scheil’s additive principle has been applied. The model was created in the finite element software ABAQUS Standard V6.13, including convection and radiation when the component was transferred from furnace to the tool as well as the air-cooling process. A USDFLD subroutine was used to model the phase transformation and a HET-VAL subroutine was used to model the latent heat. Contact heat conductance was a function of the pressure.
The authors have used techniques from their previous work on tool wear estimation for cold stamping to estimate the contact pressure on the tooling, and the amount of sliding that occurs over the tooling, and the corresponding tooling temperature. This data provides a unique data set to understand the wear on the tooling, and will eventually lead to a model for estimating tooling life.