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.

Air Entrainment in the Turbulent Ship Hull Boundary Layer

Turbulent fluctuations in the vicinity of the water free surface along a flat, vertically oriented surface-piercing plate are studied experimentally using a laboratory-scale experiment. In this experiment, a meter-wide stainless steel belt travels horizontally in a loop around two rollers with vertically oriented axes, which are separated by 7.5 meters. This belt device is mounted inside a large water tank with the water level set just below the top edge of the belt. The belt, rollers, and supporting frame are contained within a sheet metal box to keep the device dry except for one 6-meter-long straight test section between rollers. The belt is launched from rest with an acceleration of up to 3-g in order to quickly reach steady state velocity. This creates a temporally evolving boundary layer analogous to the spatially evolving boundary layer created along a flat-sided ship moving at the same velocity, with a length equivalent to the length of belt that has passed the measurement region since the belt motion began. Surface profile measurements in planes normal to the belt surface are conducted using cinematic Laser Induced Fluorescence and quantitative surface profiles are extracted at each instant in time. Using these measurements, free surface fluctuations are examined and the propagation behavior of these free surface ripples is studied. It is found that free surface fluctuations are generated in a region close to the belt surface, where sub-surface velocity fluctuations influence the behavior of these free surface features. These rapidly-changing surface features close to the belt appear to lead to the generation of freely-propagating waves far from the belt, outside the influence of the boundary layer. Sub-surface PIV measurements are performed in order to study the modification of the boundary layer flow field due to the effects of the water free surface. Cinematic planar PIV measurements are performed in horizontal planes parallel to the free surface by imaging the flow from underneath the tank, providing streamwise and wall-normal velocity fields. Additional planar PIV experiments are performed in vertical planes parallel to the belt surface in order to study the bahvior of streamwise and vertical velocity fields. It is found that the boundary layer grows rapidly near the free surface, leading to an overall thicker boundary layer close to the surface. This rapid boundary layer growth appears to be linked to a process of free surface bursting, the sudden onset of free surface fluctuations. Cinematic white light movies are recorded from beneath the water surface in order to determine the onset location of air entrainment. In addition, qualitative observations of these processes are made in order to determine the mechanisms leading to air entrainment present in this flow.

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.

Positioning of Deadeners for Vibration Reduction in Vehicle Roof Using Embedded Sensitivity

The noise, vibration and harshness (NVH) performance of passenger vehicles strongly depends on the fluid-structure interaction between the air in the vehicle cavity and the sheet metal structure of the vehicle. Most of the noise and vibration problems related to this interaction come from resonance peaks of the sheet metal, which are excited by external forces (road, engine, and wind). A reduction in these resonance peaks can be achieved by applying bitumen damping layers, also called deadeners, in the sheet metal. The problem is where these deadeners shall be fixed, which is usually done in a trial-and-error basis. In this work, one proposes the use of embedded sensitivity to locate the deadeners in the sheet metal of the vehicle, more specifically in the vehicle roof. Experimental frequency response functions (FRFs) of the roof are obtained and the data are processed by adopting the embedded sensitivity method, thus obtaining the sensitivity of the resonance peaks on the local increase in damping due to the deadeners. As a result, by examining the sensitivity functions, one can find the optimum location of the deadeners that maximize their effect in reducing the resonance peaks of interest. After locating the deadeners in the optimum positions, it was possible to verify a strong reduction in resonance peaks of the vehicle roof, thus showing the efficiency of the procedure. The main advantage of this procedure is that it only requires FRF measurements of the vehicle in its original state not needing any previous modification of the vehicle structure to find the sensitivity functions. [DOI: 10.1115/1.4000769]

A Study on the Relationship of Embedded Sensitivity With Measuring Grid and Mode Shapes

Embedded sensitivity analysis has proven to be a useful tool in finding optimum positions of structure reinforcements. However, it was not clear how sensitivities obtained from the embedded sensitivity method were related to the normal mode, or operational mode, associated to the frequency of interest. In this work, this relationship is studied based on a finite element of a slender sheet metal piece, with preponderant bending modes. It is shown that higher sensitivities always occur at nodes or antinodes of the vibrating system. [DOI: 10.1115/1.4002127]

Texture and mechanical properties evolution of a deep drawing medium carbon steel during cold rolling and subsequent recrystallization

Medium carbon steels are mostly used for simple applications; however, new applications have been developed for which good sheet metal formability is required. These types of steels have an inherent low formability. A medium-carbon hot-rolled SAE 1050 steel was selected for this study. It has been cold rolled with thickness reductions varying between 7 and 80%. The samples obtained were used to evaluate the strain hardening curve. For samples with a 50 and 80% thickness reduction, an annealing heat treatment was performed to achieve recrystallization. The material was characterized in the ""as-received"", cold rolled and annealed conditions using several methods: optical metallography, X-ray diffraction (texture), Vickers hardness, and tensile testing. For large thickness reductions, the SAE 1050 steel presented low elongation, less than 2%, and yield strength (YS) and tensile strength (TS) around 1400 MPa. Texture in the ""as-received"" condition showed strong components on the {001} plane, in the < 100 >, < 210 > and (110) directions. After cold rolling, the texture did not present any significant changes for small thickness reductions, however. It changed completely for large ones, where gamma, < 111 >//ND, alpha, < 110 > HRD, and gamma prime, < 223 >//ND, fibres were strengthened. After annealing, the microstructure of the SAE 1050 steel was characterized by recrystallized ferrite and globular cementite. There was little change in the alpha fibre for the 50% reduction, whereas for the 80% reduction, its intensity increased. Both gamma and gamma prime fibres vanished upon annealing for 50 and 80% reductions alike. (c) 2008 Elsevier B.V. All rights reserved.

Medium carbon steel deep drawing: A study on the evolution of mechanical properties, texture and simulations, from cold rolling to the end product

Medium carbon steels are mostly used for simple applications; nevertheless new applications have been developed for which good sheet formability is required. This class of steels has an inherent low formability. A medium carbon hot rolled SAE 1050 steel has been selected for this study. It has been cold rolled with reductions in the 7-80% range. Samples have been used to assess the cold work hardening curve. For samples with a 50 and 80% thickness reduction, an annealing heat treatment has been performed to obtain recrystallization. The material has been characterized in the ""as received"", cold rolled and annealed conditions, using several methods: optical microscopy, X-ray diffraction (texture), Vickers hardness and tensile testing. The 50% cold rolled and recrystallized material has been further studied in terms of sheet metal formability and texture evolution during the actual stamping of a steel toecap that has been used to validate the finite element simulations. (C) 2008 Elsevier B.V. All rights reserved.

Gutter detail, Collaborative Workshop, University of Queensland, St Lucia

Open-ended folded sheet metal gutter.

Melhoria do processo com recurso a metodologia Kaizen

Mestrado em Engenharia Electrotécnica e de Computadores

Optimização do corte de chapas

O presente trabalho visa denotar a importância de ferramentas e técnicas utilizadas como apoio à tomada de decisão. Foi proposto um problema de corte cujo objectivo primordial procura minimizar o desperdício gerado resultante do processo de obtenção de um produto, utilizando um caso representativo de um produto em chapa, fabricado por uma empresa que conta três décadas de laboração contínua, proposeram-se e realizaram-se estudos no sentido de solucionar recursos causadores de desperdício. Neste trabalho aplicou-se um problema de corte bi-dimensional a uma indústria que recorre ao fabrico de produtos em chapa, por forma a minimizar o desperdício relativo ao processo utilizado. Propôs-se quatro alternativas à solução actual realizada na empresa, que passa pela disposição e combinação de vários tipos de cortes-padrão que podem ser executados nas diferentes dimensões de matéria-prima disponibilizada. Estas alternativas têm como vantagem apresentar reduções que se traduzam significativas para os custos implícitos à realização do processo produtivo. Os estudos computacionais praticados mostraram que as soluções propostas como alternativa obtiveram melhores resultados que os obtidos pela empresa, excepto num caso.

Levantamento, reparação e beneficiação do simulador TERCO PST 2200 do Laboratório de Sistemas de Energia do ISEP

Este trabalho é baseado no simulador de redes PST2200 do Laboratório de Sistemas de Energia (LSE) pois está avariado com vários problemas conhecidos, designadamente: - Defeito de isolamento (disparo de diferencial), - Desregulação da velocidade da máquina primária (motor DC), - Circuito de excitação da máquina síncrona inoperacional, - Inexistência de esquemas elétricos dos circuitos do simulador, - Medidas desreguladas e com canais de medida com circuito impresso queimado. O trabalho executado foi: - O levantamento e desenho de raiz (não existe qualquer manual) dos esquemas dos 10 módulos do simulador, designadamente naqueles com avaria ou com desempenho problemático a fim de que se possa ter uma visão mais pormenorizada dos circuitos e seus problemas, por forma a intervir para os minimizar e resolver, - Foi realizado o diagnóstico de avaria do simulador e foram propostas soluções para os mesmos, - Realizaram-se as intervenções propostas e aprovadas. Nas intervenções realizadas, os princípios orientadores foram: - Aumentar a robustez do equipamento por forma a garantir a sua integridade a utilizações menos apropriados e manobras 'exóticas' próprias de alunos, que pela sua condição, estão em fase de aprendizagem, - Atualizar o equipamento, colocando-o em sintonia com o 'estado da arte', - Como fator de valorização suplementar, foi concebida e aplicada a supervisão remota do funcionamento do simulador através da rede informática. Foram detetados inúmeros erros: - Má ligação do motor de corrente continua ao variador, resultando a falta de controlo da frequência da rede do sistema, - Ligações entre painéis trocadas resultando em avarias diversas das fontes de alimentação, - Cartas eletrónicas de medidas avariadas e que além de se reparar, foram também calibradas. Devido ao mecenato da empresa Schnitt + Sohn participando monetariamente, fez-se o projeto de alteração e respetiva execução de grande parte do simulador aumentando a fiabilidade do mesmo, diminuindo assim a frequência das avarias naturais mais as que acontecem involuntariamente devido a este ser um instrumento didático. Além do trabalho elétrico, foi feito muito trabalho de chaparia para alteração de estrutura e suporte do material com diferenças de posicionamento. Neste trabalho dá-se também alguns exemplos de cálculo e simulação das redes de transporte que se pode efetuar no simulador como estudo e simulação de avarias num sistema produtivo real. Realizou-se a monitorização de dois aparelhos indicadores de parâmetros de energia (Janitza UMG96S) através duma rede com dois protocolos ethernet e profibus utilizando o plc (Omron CJ2M) como valorização do trabalho.

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.