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Development of techniques using finite element and meshless methods for the simulation of piercing
Author(s)
Mabogo, Mbavhalelo
Date Issued
2009
Type
Thesis
Publisher
Cape Peninsula University of Technology
Abstract
Finite element analysis modelling of sheet metal stamping is an important step in the
design of tooling and process parameters. One of the critical measurements to
determine the effectiveness of a numerical model is its capability of accurately
predicting failure modes. To be able to make accurate predictions of deformation,
tool force, blank design, etc computer simulation is almost necessary. In the
automotive industry the tooling design can now be made by computer and analysed
with FEA, and the amount of prototypes required for qualifying a design before
manufacturing commences is greatly reduced.
Tool design is a specialized phase of tool engineering. While there are many diecutting
operation, some of which are very complex, they can all be reduce to plain
blanking , piercing, lancing, cutting off and parting, notching, shaving and trimming.
The cutting action that occurs in the piercing is quite similar to that of the chip
formation ahead of a cutting tool. The punch contact the material supported by the
die and a pressure builds up occurs, When the elastic limit of the work material is the
exceeded the material begins to flow plastically (plastic deformation). It is often
impractical to pierce holes while forming, or before forming because they would
become distorted in the forming operation.
The aim of the research is to develop techniques that would reduce the amount time
spent during the tool qualifying stage. By accurately setting a finite element
simulation that closely matches the experimental or real-life situation we can great
understand the material behaviour and properties before tool designing phase
commences. In this analysis, during the piercing process of the drainage hole for a
shock absorber seat, there is visible material tearing (on the neck) which as a result
the component is rejected. This results in material wastage, and prolonged cycle time
since the operation has to be now done separately at a different workstation.
design of tooling and process parameters. One of the critical measurements to
determine the effectiveness of a numerical model is its capability of accurately
predicting failure modes. To be able to make accurate predictions of deformation,
tool force, blank design, etc computer simulation is almost necessary. In the
automotive industry the tooling design can now be made by computer and analysed
with FEA, and the amount of prototypes required for qualifying a design before
manufacturing commences is greatly reduced.
Tool design is a specialized phase of tool engineering. While there are many diecutting
operation, some of which are very complex, they can all be reduce to plain
blanking , piercing, lancing, cutting off and parting, notching, shaving and trimming.
The cutting action that occurs in the piercing is quite similar to that of the chip
formation ahead of a cutting tool. The punch contact the material supported by the
die and a pressure builds up occurs, When the elastic limit of the work material is the
exceeded the material begins to flow plastically (plastic deformation). It is often
impractical to pierce holes while forming, or before forming because they would
become distorted in the forming operation.
The aim of the research is to develop techniques that would reduce the amount time
spent during the tool qualifying stage. By accurately setting a finite element
simulation that closely matches the experimental or real-life situation we can great
understand the material behaviour and properties before tool designing phase
commences. In this analysis, during the piercing process of the drainage hole for a
shock absorber seat, there is visible material tearing (on the neck) which as a result
the component is rejected. This results in material wastage, and prolonged cycle time
since the operation has to be now done separately at a different workstation.
Additional information
Thesis (MTech (Mechanical Engineering))--Cape Peninsula University of Technology, 2009
Subjects
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