The Metal worker : a weekly journal of the stove, roofing, cornice, tin, plumbing and heating trades.

Description based on: volume 39, no. 1 (Jan. 7, 1893); title from caption.

Experimental study of forces and energies during shearing of steel sheet with angled tools

Shearing is a fast and inexpensive method to cut sheet metal that has been used since the beginning of the industrialism. Consequently, published experimental studies of shearing can be found from over a century back in time. Recent studies, however, are due to the availability of low cost digital computation power, mostly based on finite element simulations that guarantees quick results. Still, for validation of models and simulations, accurate experimental data is a requisite. When applicable, 2D models are in general desirable over 3D models because of advantages like low computation time and easy model formulation. Shearing of sheet metal with parallel tools is successfully modelled in 2D with a plane strain approximation, but with angled tools the approximation is less obvious. Therefore, plane strain approximations for shearing with angled tools were evaluated by shear experiments of high accuracy. Tool angle, tool clearance, and clamping of the sheet were varied in the experiments. The results showed that the measured forces in shearing with angled tools can be approximately calculated using force measurements from shearing with parallel tools. Shearing energy was introduced as a quantifiable measure of suitable tool clearance range. The effects of the shearing parameters on forces were in agreement with previous studies. Based on the agreement between calculations and experiments, analysis based on a plane strain assumption is considered applicable for angled tools with a small (up to 2 degrees) rake angle.

Design and application of experimental methods for steel sheet shearing

Shearing is the process where sheet metal is mechanically cut between two tools. Various shearing technologies are commonly used in the sheet metal industry, for example, in cut to length lines, slitting lines, end cropping etc. Shearing has speed and cost advantages over competing cutting methods like laser and plasma cutting, but involves large forces on the equipment and large strains in the sheet material. The constant development of sheet metals toward higher strength and formability leads to increased forces on the shearing equipment and tools. Shearing of new sheet materials imply new suitable shearing parameters. Investigations of the shearing parameters through live tests in the production are expensive and separate experiments are time consuming and requires specialized equipment. Studies involving a large number of parameters and coupled effects are therefore preferably performed by finite element based simulations. Accurate experimental data is still a prerequisite to validate such simulations. There is, however, a shortage of accurate experimental data to validate such simulations. In industrial shearing processes, measured forces are always larger than the actual forces acting on the sheet, due to friction losses. Shearing also generates a force that attempts to separate the two tools with changed shearing conditions through increased clearance between the tools as result. Tool clearance is also the most common shearing parameter to adjust, depending on material grade and sheet thickness, to moderate the required force and to control the final sheared edge geometry. In this work, an experimental procedure that provides a stable tool clearance together with accurate measurements of tool forces and tool displacements, was designed, built and evaluated. Important shearing parameters and demands on the experimental set-up were identified in a sensitivity analysis performed with finite element simulations under the assumption of plane strain. With respect to large tool clearance stability and accurate force measurements, a symmetric experiment with two simultaneous shears and internal balancing of forces attempting to separate the tools was constructed. Steel sheets of different strength levels were sheared using the above mentioned experimental set-up, with various tool clearances, sheet clamping and rake angles. Results showed that tool penetration before fracture decreased with increased material strength. When one side of the sheet was left unclamped and free to move, the required shearing force decreased but instead the force attempting to separate the two tools increased. Further, the maximum shearing force decreased and the rollover increased with increased tool clearance. Digital image correlation was applied to measure strains on the sheet surface. The obtained strain fields, together with a material model, were used to compute the stress state in the sheet. A comparison, up to crack initiation, of these experimental results with corresponding results from finite element simulations in three dimensions and at a plane strain approximation showed that effective strains on the surface are representative also for the bulk material. A simple model was successfully applied to calculate the tool forces in shearing with angled tools from forces measured with parallel tools. These results suggest that, with respect to tool forces, a plane strain approximation is valid also at angled tools, at least for small rake angles. In general terms, this study provide a stable symmetric experimental set-up with internal balancing of lateral forces, for accurate measurements of tool forces, tool displacements, and sheet deformations, to study the effects of important shearing parameters. The results give further insight to the strain and stress conditions at crack initiation during shearing, and can also be used to validate models of the shearing process.

Experimental study of strain fields during shearing of medium and high-strength steel sheet

There is a shortage of experimentally determined strains during sheet metal shearing. These kinds of data are a requisite to validate shearing models and to simulate the shearing process. In this work, strain fields were continuously measured during shearing of a medium and a high strength steel sheet, using digital image correlation. Preliminary studies based on finite element simulations, suggested that the effective surface strains are a good approximation of the bulk strains below the surface. The experiments were performed in a symmetric set-up with large stiffness and stable tool clearances, using various combinations of tool clearance and clamping configuration. Due to large deformations, strains were measured from images captured in a series of steps from shearing start to final fracture. Both the Cauchy and Hencky strain measures were considered, but the difference between these were found negligible with the number of increments used (about 20 to 50). Force-displacement curves were also determined for the various experimental conditions. The measured strain fields displayed a thin band of large strain between the tool edges. Shearing with two clamps resulted in a symmetric strain band whereas there was an extended area with large strains around the tool at the unclamped side when shearing with one clamp. Furthermore, one or two cracks were visible on most of the samples close to the tool edges well before final fracture. The fracture strain was larger for the medium strength material compared with the high-strength material and increased with increasing clearance.

Correlating The Features Of Topography To Friction By Sliding Experiments

Friction can influence the quality of the finished product to a large extent in certain manufacturing processes. Sheet metal forming is a particular case, where the friction between the hard-die and the relatively soft work-piece can be extremely important. Under such conditions, topography of the harder surface can influence the resistance to traction at the interface. This paper discusses about the correlation between certain features of the surface; topography and coefficient of friction based on experiments involving sliding of a few soft metal pins against a harder material. A brief description of the experimental procedure and the analysis are presented. A hybrid parameter which encapsulates both the amplitude features as well as the relative packing of peaks is shown to correlate well with the coefficient of friction.

人工神经网络技术在板料激光弯曲中的应用

基于人工神经网络基本理论,建立在板料激光弯曲中预测材料表面最高温度、弯曲角度的BP网络模型.借助于MATLAB仿真软件中的神经网络工具箱作为开发平台,将试验样本数据和经过试验验证的数值计算结果作为补充的样本数据用于BP网络的训练,利用训练好的BP网络对非线性的样本数据规律进行拟合,实现激光加工工艺参数的优化,为实际生产和加工提供有效的依据.

薄板激光弯曲温度场的数值模拟与校验

采用MSC.Marc非线性有限元软件，对薄板激光变曲过程中的温度场进行了数值模拟，得到了引起薄板激光弯曲形的温度场的变化规律。通过温度传感器测量与激光扫描线相对应的薄板下表面温度变化的规律来验证数值模拟的结果。模拟值与实测值基本吻合，表明数值模拟结果可作为激光加工工艺参数选择的依据。

板料激光弯曲试验

针对大飞机壁板用的铝合金板料AA6056进行激光弯曲过程的试验研究.试验选用厚度为1.0 mm和2.5 mm的薄板,采用多组不同的工艺参数进行对比分析.采用直径0.1 mm的镍铬.镍硅热电偶作为温度传感器,YOKOGAWA MV200型便携式记录仪测量板料表面的温度;使用MV.1300UM CCD拍摄板料激光弯曲变形的过程,通过自行开发的实时采集软件记录并进行图像处理,最终得到了板料激光弯曲变形过程的实测曲线.试验结果为该过程的数值模拟提供了更为精确的验证依据,为深入研究板料激光弯曲过程奠定了试验基础.

Análisis del proceso de Friction Drilling: Análisis de la calidad de la junta atornillada

[ES]En el presente trabajo, se pretende optimizar la unión atornillada de chapas de dos materiales disimilares (acero y aluminio) mediante un proceso no convencional, el taladrado por fricción. Dicho proceso está orientado a la calderería fina, sector en el cual tiene gran número de aplicaciones. Se comenzará con una serie de ensayos iníciales y se procederá a realizar pruebas sistemáticas. Se realizarán mediciones de temperaturas, momentos torsores y fuerzas, y se analizaran las tolerancias dimensionales generadas por el proceso para la elección de los parámetros óptimos. El documento se centrará en analizar de forma teórica el comportamiento mecánico de la unión y de los ensayos de tracción correspondientes. Esto servirá para realizar los futuros ensayos de calidad y posteriormente comparar los resultados con los de las uniones convencionales.

Caracterização experimental e modelação numérica de espumas metálicas

As espumas de alumínio são materiais ultraleves, o que as torna atractivas para um largo espectro de aplicações comerciais na área da defesa, na indústria automóvel e aeroespacial, entre outras. Actualmente, há um grande interesse na utilização de espumas de alumínio em componentes estruturais ultraleves, incorporados em sistemas de absorção de energia para protecção contra o impacto. O recurso à simulação numérica para resolver problemas de engenharia em várias áreas é cada vez mais comum. A modelação numérica dos materiais assume vital importância quando o problema envolve a análise de processos tecnológicos como, por exemplo, a conformação plástica de materiais, ou a análise de estruturas. Deste modo, torna-se imprescindível garantir que a modelação dos materiais é de tal forma rigorosa que permite simular o melhor possível o seu comportamento real nas condições concretas da análise a realizar. A forma mais comum de garantir o rigor dos modelos utilizados é a validação dos modelos numéricos tendo por base resultados experimentais. Neste trabalho, fez-se a caracterização do comportamento mecânico das espumas de alumínio com nome comercial ALPORAS!, obtidas pelo processo de fabrico denominado expansão directa do metal fundido por adição de um agente expansor. Esta caracterização consistiu num conjunto de ensaios experimentais quer no regime quasi-estático, quer no regime dinâmico. No regime quasi-estático realizaram-se ensaios de compressão uniaxial e de compressão multiaxial. Para a caracterização no regime dinâmico foram realizados ensaios em barras de Hopkinson de polimetil-metacrilato (PMMA). Com base nos resultados experimentais obtidos determinaram-se os parâmetros dos dois modelos constitutivos para espumas metálicas implementados no programa comercial Abaqus™/Explicit. Estes modelos, e os respectivos parâmetros determinados, foram validados reproduzindo numericamente alguns ensaios experimentais quasi-estáticos e dinâmicos. Assim, verificou-se a adequabilidade dos modelos em diversas condições quer em termos de esforços quer em termos de regime de taxa de deformação Por último, desenvolveu-se uma estrutura inovadora para absorção de energia durante um impacto, constituída por componentes perfilados em liga de alumínio e por componentes em espumas de alumínio. Esta estrutura foi testada exclusivamente com recurso à simulação numérica, utilizando os modelos constitutivos validados anteriormente.

Projecto de sistema de fixação de punções para quinadoras hidráulicas

Mestrado em Engenharia Mecânica - Construções Mecânicas

Desenvolvimento de sistema de apoio dinâmico da chapa no corte em guilhotina

Guilhotinas são máquinas robustas, de corte rectilíneo, normalmente associadas a equipamentos de baixo custo, devido à pequena quantidade de dispositivos tecnológicos incorporados. No entanto, esta situação pode ser alterada através da criatividade dos projetistas deste tipo de equipamento. Analisando algumas operações específicas, pode-se observar que algumas ferramentas, quando associadas ao equipamento, podem aumentar substancialmente a produtividade do processo de corte e a qualidade do produto final. Em relação ao processo de corte de chapas finas de metal, pode-se observar que na fase final de corte, o peso do material a cortar é suspenso por uma pequena porção de material que ainda não foi sujeita ao corte. Este facto leva a uma deformação plástica nesta última zona, causando problemas de qualidade no produto final, que não ficará completamente plano. Este trabalho foi desenvolvido em torno deste problema, estudando a melhor solução para desenvolver uma nova ferramenta, capaz de evitar a falta de nivelamento da placa, após corte. Um novo equipamento foi concebido, capaz de ser facilmente incorporado na guilhotina, permitindo o acompanhamento da inclinação da lâmina durante a operação de corte. O sistema é totalmente automatizado, sendo operado por uma única instrução de corte dada pelo operador da máquina. Este sistema permite à empresa fabricante aumentar o valor agregado de cada máquina, oferecendo aos clientes soluções avançadas, contribuindo desta forma para a sustentabilidade do negócio da empresa.

Estudo de Ferramentas FEA Comerciais na Simulação Numérica de Processos de Conformação de Chapas Metálicas. Aplicação à Indústria Automóvel.

Os componentes obtidos através da conformação plástica de chapas têm uma grande importância, tanto na etapa de concepção do produto como na etapa de produção na indústria automóvel. Isto comprova-se pelo facto de, em média, cada automóvel integrar cerca de 500 componentes estampados para construir o chassis e a carroçaria [Alves 2003]. Deste total de componentes, 50 são de grandes dimensões (portas, tejadilho, painéis inferior e laterais, entre outros) e necessitam, em média, de cinco ferramentas para o seu fabrico, sendo o custo estimado para cada ferramenta de 230 000 € [Col 2000, Alves 2003]. Para além da indústria automóvel, a conformação plástica de chapas metálicas é um processo tecnológico presente nas indústrias relativas à aeroespacial, petrolífera, decoração, alimentar, entre outras. Do ponto de vista do enquadramento económico, cerca de 20% do custo total de um automóvel novo é devido à incorporação de componentes metálicos estampados. [Alves 2003]. A pressão do “Mercado Global” faz com que os custos relativos à matéria-prima, energia e mão-de-obra sejam uma constante em termos de redução do seu impacte no orçamento das empresas fornecedoras destes produtos. É neste contexto que surge a necessidade da realização deste estudo de Benchmark de Softwares, tornando-se bastante importante, quer ao nível da competitividade industrial, quer ao nível da inovação para novos produtos. A análise por elementos finitos desempenha um papel primordial no tryout virtual e otimização das ferramentas e processos de conformação plástica. Os objetivos principais deste estudo de simulação numérica são a identificação e comparação dos resultados obtidos pelo AUTOFORM e pelo PAMSTAMP, para cada uma das variáveis identificadas como as mais influentes na robustez dos processos de estampagem de chapa metálica. Estas variáveis identificadas são: consumo de material (Draw-in) após conformação; forças de conformação; valores de variação de espessura e dos valores de extensão e resultados de Springback. Os resultados obtidos são comparados com os resultados experimentais e, desta forma, avalia-se a capacidade inovadora e a eficácia de cada um dos softwares, obtendo-se assim, uma orientação mais real para o software mais indicado aos objetivos impostos pela indústria automóvel. Para este efeito, a indústria automóvel, como maior impulsionador e motor da investigação na área da simulação numérica aplicada aos processos de estampagem, tem aderido em peso ao Benchmarking. Um exemplo disto, é o que acontece nas conferências Numisheet. O Benchmark #2 da conferência Numisheet 2008 é analisado pormenorizadamente e os resultados numéricos e experimentais são comparados e apresentados. Dois materiais distintos (aço HC260LAD e liga de alumínio AC170), assim como três modelos com geometrias diferentes (com e sem freios) são apresentados neste relatório. Com vista à redução dos ciclos tentativa-erro, tem-se adotado ciclos virtuais ou numéricos e tem-se incrementado a interatividade entre as fases de concepção e projeto, num conceito muito próprio, mas cada vez mais abrangente, denominado “produção virtual”. É nesta filosofia que se insere a simulação numérica dos processos de conformação de chapa.

Fliesslochformen und Gewindefurchen in dünne Bleche und Rohre aus Kupfer und Kupferlegierungen

This thesis in Thermal Flow Drilling and Flowtap in thin metal sheet and pipes of copper and copper alloys had as objectives to know the comportment of copper and copper alloys sheet metal during the Thermal Flow Drill processes with normal tools, to know the best Speed and Feed machine data for the best bushing quality, to known the best Speed for Form Tapping processes and to know the best bush long in pure copper pipes for water solar interchange equipment. Thermal Flow Drilling (TFD) and Form Tapping (FT) is one of the research lines of the Institute of Production and Logistics (IPL) at University of Kassel. At December 1995, a work meeting of IPL, Santa Catarina University, Brazil, Buenos Aires University, Argentine, Tarapacá University (UTA), Chile members and the CEO of Flowdrill B.V. was held in Brazil. The group decided that the Manufacturing Laboratory (ML) of UTA would work with pure copper and brass alloys sheet metal and pure copper pipes in order to develop a water interchange solar heater. The Flowdrill BV Company sent tools to Tarapacá University in 1996. In 1999 IPL and the ML carried out an ALECHILE research project promoted by the DAAD and CONICyT in copper sheet metal and copper pipes and sheet metal a-brass alloys. The normal tools are lobed, conical tungsten carbide tool. When rotated at high speed and pressed with high axial force into sheet metal or thin walled tube generated heat softens the metal and allows the drill to feed forward produce a hole and simultaneously form a bushing from the displacement material. In the market exist many features but in this thesis is used short and longs normal tools of TFD. For reach the objectives it was takes as references four qualities of the frayed end bushing, where the best one is the quality class I. It was used pure copper and a-brass alloys sheet metals, with different thickness. It was used different TFD drills diameter for four thread type, from M-5 to M10. Similar to the Aluminium sheet metals studies it was used the predrilling processes with HSS drills around 30% of the TFD diameter (1,5 – 3,0 mm D). In the next step is used only 2,0 mm thick metal sheet, and 9,2 mm TFD diameter for M-10 thread. For the case of pure commercial copper pipes is used for ¾” inch diameter and 12, 8 mm (3/8”) TFD drill for holes for 3/8” pipes and different normal HSS drills for predrilling processes. The chemical sheet metal characteristics were takes as reference for the material behaviour. The Chilean pure copper have 99,35% of Cu and 0,163% of Zinc and the Chilean a-brass alloys have 75,6% of Cu and 24,0% of Zinc. It is used two German a-brass alloys; Nº1 have 61,6% of Cu, 36,03 % of Zinc and 2,2% of Pb and the German a-brass alloys Nº2 have 63,1% of Cu, 36,7% of Zinc and 0% of Pb. The equipments used were a HAAS CNC milling machine centre, a Kistler dynamometer, PC Pentium II, Acquisition card, TESTPOINT and XAct software, 3D measurement machine, micro hardness, universal test machine, and metallographic microscope. During the test is obtained the feed force and momentum curves that shows the material behaviour with TFD processes. In general it is take three phases. It was possible obtain the best machining data for the different sheet of copper and a-brass alloys thick of Chilean materials and bush quality class I. In the case of a-brass alloys, the chemical components and the TFD processes temperature have big influence. The temperature reach to 400º Celsius during the TFD processes and the a-brass alloys have some percents of Zinc the bush quality is class I. But when the a-brass alloys have some percents of Lead who have 200º C melting point is not possible to obtain a bush, because the Lead gasify and the metallographic net broke. During the TFD processes the recrystallization structures occur around the Copper and a-brass alloy bush, who gives more hardness in these zones. When the threads were produce with Form Tapping processes with Flowtap tools, this hardness amount gives a high limit load of the thread when hey are tested in a special support that was developed for it. For eliminated the predrilling processes with normal HSS drills it was developed a compound tool. With this new tool it was possible obtain the best machining data for quality class I bush. For the copper pipes it is made bush without predrilling and the quality class IV was obtained. When it is was used predrilling processes, quality classes I bush were obtained. Then with different HSS drill diameter were obtained different long bush, where were soldering with four types soldering materials between pipes with 3/8” in a big one as ¾”. Those soldering unions were tested by traction test and all the 3/8” pipes broken, and the soldering zone doesn’t have any problem. Finally were developed different solar water interchange heaters and tested. As conclusions, the present Thesis shows that the Thermal Flow Drilling in thinner metal sheets of cooper and cooper alloys needs a predrilling process for frayed end quality class I bushings, similar to thinner sheets of aluminium bushes. The compound tool developed could obtain quality class I bushings and excludes predrilling processes. The bush recrystalization, product of the friction between the tool and the material, the hardness grows and it is advantageous for the Form Tapping. The methodology developed for commercial copper pipes permits to built water solar interchange heaters.

Contribución al estudio del proceso de doblado al aire de chapa. Modelo de predicción del ángulo de recuperación y del radio de doblado final

Modelo de predicción de la geometría final de una pieza de chapa, radio y ángulo de doblado final, producida mediante un proceso de doblado al aire.