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.

Characterising material and process variation effects on springback robustness for a semi-cylindrical sheet metal forming process

Variation in the incoming sheet material and fluctuations in the press setup is unavoidable in many stamping plants. The effect of these variations can have a large influence on the quality of the final stamping, in particular, unpredictable springback of the sheet when the tooling is removed. While stochastic simulation techniques have been developed to simulate this problem, there has been little research that connects the influence of the noise sources to springback. This paper characterises the effect of material and process variation on the robustness of springback for a semi-cylindrical channel forming operation, which shares a similar cross-section profile as many automotive structural components. The study was conducted using the specialised sheet metal forming package AutoForm^TM Sigma, for which a series of stochastic simulations were performed with each of the noise sources incrementally introduced. The effective stress and effective strain scatter in a critical location of the part was examined and a response window, which indicates the respective process robustness, was defined. The incremental introduction of the noise sources allows the change in size of the stressstrain response window to be tracked. The results showed that changes to process variation parameters, such as BHP and friction coefficient, directly affect the strain component of the stressstrain response window by altering the magnitude of external work applied to forming system. Material variation, on the other hand, directly affected the stress component of the response window. A relationship between the effective stressstrain response window and the variation in springback was also established.

Students in the Sheet Metal Department at Work

A view of students at work in a classroom in the Sheet Metal Department at the New York Trade School. Black and white photograph.

Transient Temperature Distribution in a Sheet Metal by Low-Energy Laser Scanning

Low-energy laser-heating techniques are widely used in engineering applications such as, thinfilm deposition, surface treatment, metal forming and micro-structural pattern formation. In this paper,under the conditions of ignoring the thermo-mechanical coupling, a numerical simulation on the spatialand temporal temperature distribution in a sheet metal produced by the laser beam scanning in virtue of thefinite element method is presented. Both the three-dimensional transient temperature field and thetemperature evolution as a function of heat penetrating depth in the metal sheet are calculated. Thetemperature dependence of material properties was taken into account. It was shown that, after taking thetemperature dependence of the material absorbance effect into consideration, the temperature change ratealong the scanning direction and the temperature maximum were both increased.

Development of modelling method selection tool for health services management: From problem structuring methods to modelling and simulation methods

Background: There is an increasing recognition that modelling and simulation can assist in the process of designing health care policies, strategies and operations. However, the current use is limited and answers to questions such as what methods to use and when remain somewhat underdeveloped. Aim. The aim of this study is to provide a mechanism for decision makers in health services planning and management to compare a broad range of modelling and simulation methods so that they can better select and use them or better commission relevant modelling and simulation work. Methods. This paper proposes a modelling and simulation method comparison and selection tool developed from a comprehensive literature review, the research team's extensive expertise and inputs from potential users. Twenty-eight different methods were identified, characterised by their relevance to different application areas, project life cycle stages, types of output and levels of insight, and four input resources required (time, money, knowledge and data). Results: The characterisation is presented in matrix forms to allow quick comparison and selection. This paper also highlights significant knowledge gaps in the existing literature when assessing the applicability of particular approaches to health services management, where modelling and simulation skills are scarce let alone money and time. Conclusions: A modelling and simulation method comparison and selection tool is developed to assist with the selection of methods appropriate to supporting specific decision making processes. In particular it addresses the issue of which method is most appropriate to which specific health services management problem, what the user might expect to be obtained from the method, and what is required to use the method. In summary, we believe the tool adds value to the scarce existing literature on methods comparison and selection. © 2011 Jun et al.

A Videogrammetric As-Built Data Collection Method for Digital Fabrication of Sheet Metal Roof Panels

A roofing contractor typically needs to acquire as-built dimensions of a roof structure several times over the course of its build to be able to digitally fabricate sheet metal roof panels. Obtaining these measurements using the exiting roof surveying methods could be costly in terms of equipment, labor, and/or worker exposure to safety hazards. This paper presents a video-based surveying technology as an alternative method which is simple to use, automated, less expensive, and safe. When using this method, the contractor collects video streams with a calibrated stereo camera set. Unique visual characteristics of scenes from a roof structure are then used in the processing step to automatically extract as-built dimensions of roof planes. These dimensions are finally represented in a XML format to be loaded into sheet metal folding and cutting machines. The proposed method has been tested for a roofing project and the preliminary results indicate its capabilities.

A novel process for transforming sheet metal blanks: Ridged die forming

Up to 20% of all sheet metal produced is scrapped as blanking skeletons. A novel process is therefore designed and examined, aiming to transform tessellating 'pre-blanks' in-plane into the real blanks required for stamping. Prior to blanking, the sheet is formed with a set of ridged dies, from which pre-blanks are cut and then flattened into true blanks. Several different approaches to designing ridged dies are evaluated by simulation and experiment, and the best results demonstrate a potential reduction in blanking yield losses for can-making from 9.3% to 6.9%. © 2013 CIRP.

Mode I fracture of sheet metal

The perceived wisdom about thin sheet fracture is that (i) the crack propagates under mixed mode I & III giving rise to a slant through-thickness fracture profile and (ii) the fracture toughness remains constant at low thickness and eventually decreases with increasing thickness. In the present study, fracture tests performed on thin DENT plates of various thicknesses made of stainless steel, mild steel, 6082-O and NS4 aluminium alloys, brass, bronze, lead, and zinc systematically exhibit (i) mode I “bath-tub”, i.e. “cup & cup”, fracture profiles with limited shear lips and significant localized necking (more than 50% thickness reduction), (ii) a fracture toughness that linearly increases with increasing thickness (in the range of 0.5–5 mm). The different contributions to the work expended during fracture of these materials are separated based on dimensional considerations. The paper emphasises the two parts of the work spent in the fracture process zone: the necking work and the “fracture” work. Experiments show that, as expected, the work of necking per unit area linearly increases with thickness. For a typical thickness of 1 mm, both fracture and necking contributions have the same order of magnitude in most of the metals investigated. A model is developed in order to independently evaluate the work of necking, which successfully predicts the experimental values. Furthermore, it enables the fracture energy to be derived from tests performed with only one specimen thickness. In a second modelling step, the work of fracture is computed using an enhanced void growth model valid in the quasi plane stress regime. The fracture energy varies linearly with the yield stress and void spacing and is a strong function of the hardening exponent and initial void volume fraction. The coupling of the two models allows the relative contributions of necking versus fracture to be quantified with respect to (i) the two length scales involved in this problem, i.e. the void spacing and the plate thickness, and (ii) the flow properties of the material. Each term can dominate depending on the properties of the material which explains the different behaviours reported in the literature about thin plate fracture toughness and its dependence with thickness.

Sheet Metal Department Sign

This is a black and white photograph of a sign for the Sheet Metal Department of the New York Trade School likely created by the department. It contains ornate metal work and displays the year 1938, probably the beginning year of the Sheet Metal Department.

Design and validation of a sheet metal shearing experimental procedure

Throughout the industrial processes of sheet metal manufacturing and refining, shear cutting is widely used for its speed and cost advantages over competing cutting methods. Industrial shears may include some force measurement possibilities, but the force is most likely influenced by friction losses between shear tool and the point of measurement, and are in general not showing the actual force applied to the sheet. Well defined shears and accurate measurements of force and shear tool position are important for understanding the influence of shear parameters. Accurate experimental data are also necessary for calibration of numerical shear models. Here, a dedicated laboratory set-up with well defined geometry and movement in the shear, and high measurability in terms of force and geometry is designed, built and verified. Parameters important to the shear process are studied with perturbation analysis techniques and requirements on input parameter accuracy are formulated to meet experimental output demands. Input parameters in shearing are mostly geometric parameters, but also material properties and contact conditions. Based on the accuracy requirements, a symmetric experiment with internal balancing of forces is constructed to avoid guides and corresponding friction losses. Finally, the experimental procedure is validated through shearing of a medium grade steel. With the obtained experimental set-up performance, force changes as result of changes in studied input parameters are distinguishable down to a level of 1%.

Application of bending under tension test to determine the effect of tool radius and the contact pressure on the coefficient of friction in sheet metal forming

To quantify the frictional behaviour in sheet forming operations, several laboratory experiments which simulate the real forming conditions are performed. The Bending Under Tension Test is one such experiment which is often used to represent the frictional flow of sheet material around a die or a punch radius. Different mathematical representations are used to determine the coefficient of friction in the Bending Under Tension Test. In general the change in the strip thickness in passing over the die radius is neglected and the radius of curvature to thickness ratio is assumed to be constant in these equations. However, the effect of roller radius, sheet thickness and the surface pressure are also omitted in some of these equations. This work quantitatively determined the effect of roller radius and the tooling pressure on the coefficient of friction. The Bending Under Tension Test was performed using rollers with different radii and also lubricants with different properties. The tool radii were found to have a direct influence in the contact pressure. The effect of roller radius on friction was considerable and it was observed that there is a clear relationship between the contact pressure and the coefficient of friction.

Improving an inverse model of sheet metal forming by neural network based regression

An inverse model for a sheet meta l forming process aims to determine the initial parameter levels required to form the final formed shape. This is a difficult problem that is usually approached by traditional methods such as finite element analysis. Formulating the problem as a classification problem makes it possible to use well established classification algorithms, such as decision trees. Classification is, however, generally based on a winner-takes-all approach when associating the output value with the corresponding class. On the other hand, when formulating the problem as a regression task, all the output values are combined to produce the corresponding class value. For a multi-class problem, this may result in very different associations compared with classification between the output of the model and the corresponding class. Such formulation makes it possible to use well known regression algorithms, such as neural networks. In this paper, we develop a neural network based inverse model of a sheet forming process, and compare its performance with that of a linear model. Both models are used in two modes, classification mode and a function estimation mode, to investigate the advantage of re-formulating the problem as a function estimation. This results in large improvements in the recognition rate of set-up parameters of a sheet metal forming process for both models, with a neural network model achieving much more accurate parameter recognition than a linear model.

Multivariate modelling of variability in sheet metal forming

The inherent variability in incoming material and process conditions in sheet metal forming makes quality control and the maintenance of consistency extremely difficult. A single FEM simulation is successful at predicting the formability for a given system, however lacks the ability to capture the variability in an actual production process due to the numerical deterministic nature. This paper investigates a probabilistic analytical model where the variation of five input parameters and their relationship to the sensitivity of springback in a stamping process is examined. A range of sheet tensions are investigated, simulating different operating windows in an attempt to highlight robust regions where the distribution of springback is small. A series of FEM simulations were also performed, to compare with the findings from the analytical model using AutoForm Sigma v4.04 and to validate the analytical model assumptions.

Results show that an increase in sheet tension not only decreases springback, but more importantly reduces the sensitivity of the process to variation. A relative sensitivity analysis has been performed where the most influential parameters and the changes in sensitivity at various sheet tensions have been investigated. Variation in the material parameters, yield stress and n-value were the most influential causes of springback variation, when compared to process input parameters such as friction, which had a small effect. The probabilistic model presented allows manufacturers to develop a more comprehensive assessment of the success of their forming processes by capturing the effects of inherent variation.