Temperature-dependent anisotropic material modeling of the sheet metal component within the polymer injection forming process

In the course of this work, an extended material model for a carbon steel sheet metal has been developed based on Hill’48 yield criterion, considering temperature-dependent plastic anisotropy coefficients. This material model is applied on a polymer injection forming process in which the sheet metal heats up to a critical forming temperature through the contact with the plastic melt. At this temperature range blue brittleness occurs. The elastic properties, the yield stress as well as the plastic anisotropy coefficients of the sheet material become significantly different compared to those at room temperature. It should be emphasized that especially temperature-dependent anisotropy coefficients are not yet considered in most common material models. With the help of the presented modelling approach a more precise modelling of the temperature-dependent carbon steel material behavior can be realised.     

Process Design for Hybrid Sheet Metal Components

The global trends towards improving fuel efficiency and reducing CO_2 emissions are the key drivers for lightweight solutions. In sheet metal processing, this can be achieved by the use of materials with a supreme strength-toweight and stiffness-to-weight ratio. Besides monolithic materials such as high-strength or light metals, in particular metal–plastic composite sheets are able to provide outstanding mechanical properties. Thus, the adaption of conventional, wellestablished forming methods for the processing of hybrid sheet metals is a current challenge for the sheet metal working industry. In this work, the planning phase for a conventional sheet metal forming process is studied aiming at the forming of metal–plastic composite sheets. The single process steps like material characterization, FE analysis, tool design and development of robust process parameters are studied in detail and adapted to the specific properties of metal–plastic composites. In material characterization, the model of the hybrid laminate needs to represent not only the mechanical properties of the individual combined materials, but also needs to reflect the behaviour of the interface zone between them.Based on experience, there is a strong dependency on temperature as well as strain rate. While monolithic materials show a moderate anisotropic behaviour, loads on laminates in different directions generate different strain states and completely different failure modes. During the FE analysis, thermo-mechanic and thermo-dynamic effects influence the temperature distribution within tool and work pieces and subsequently the forming behaviour. During try out and production phase,those additional influencing factors are limiting the process window even more and therefore need to be considered for the design of a robust forming process. A roadmap for sheet metal forming adjusted to metal–plastic composites is presented in this paper.     

Mathematical modelling as a means to bridge the gap between material and tooling

The mathematical modelling of sheet-metal forming is a major focal point of current research in the field of deep-drawing world-wide. To date, however, most research efforts have been concentrated within the automotive industry.

Mathematical modelling in its initial form can be seen as an aid in understanding the material behaviour as sheet metal is transformed from a flat sheet to a hollow body. On a more sophisticated level, mathematical modelling has come to be regarded as a powerful tool with tremendous economic impact.

Decision makers in the automotive industry are increasingly under pressure to reduce development time whilst simultaneously improving product quality, minimizing risks and preventing mis-development. By supporting decisions in the initial stages of research and development and by providing feasibility results before a product even exists, mathematical modelling can decrease product-to-market time significantly.

Taking an oil-pan, which is difficult to stamp, as an example, it will be demonstrated how the part is designed using CAD data and how these data are transferred into an appropriate part and tooling network. The stresses and strains of the sheet are calculated by means of a constitutive law for deep-drawing which takes into account an elastic region, a large inelastic deformation, general hardening behaviour and anisotropy. A state-of-the-art supercomputer is used to carry out the modelling and simulation.     

板料零件数控渐进成形工艺研究

板料零件数控渐进成形工艺是一种通过数字控制设备 ,采用预先编制好的控制程序逐点成形板料零件的柔性加工工艺。本文就板料零件数控渐进成形工艺的成形过程、变形机理、极限半顶角等方面进行了探讨。认为 ,板料零件数控渐进成形是使板料的厚度减薄 ,表面积增大 ,靠逐次的变形累积产生整体的变形。变形区厚度的变化与成形半顶角有关 ,其中 ,成形极限半顶角是数控渐进成形能否成功的关键 ,它不仅与材料有关 ,而且与板料厚度有关。     

板料冲压成形毛料计算方法研究进展

较准确地计算毛料外形,可以提高板料的可成形性、材料利用率和生产率。综述了板料冲压成形毛料计算的各种方法,提出了板料冲压成形毛料计算今后的研究发展方向。     

塑性成形过程摩擦测试的研究进展

摩擦是影响金属塑性成形及其过程有限元模拟的重要因素 ,因此有必要对其测试方法进行研究。本文介绍塑性成形过程摩擦测试研究方法和测试技术的研究现状与进展 ,并对模拟试验法和直接测量法各自的特点进行了分析。作者设计出一种新型的探针传感器 ,开发出了铝合金板料温成形过程摩擦在线检测系统 ,并对铝合金板(5 182 )圆筒形件温成形过程进行了摩擦测试。     

Tool development based on modelling and simulation of hot sheet metal forming of Ti-6Al-4V titanium alloy

In the aero engine industry alternative manufacturing processes for load carrying aero engine structures imply fabrication. The concept of fabrication involves simple forgings, sheet metals and small ingots of e.g. titanium alloys which are welded together and heat treated. In the concept phase of the product development process, accurate evaluations of candidate manufacturing processes with short lead times are crucial. In the design of sheet metal forming processes, the manual die try out of deep drawing tools is traditionally a time consuming, expensive and inexact process. The present work investigates the possibility to design hot forming tools, with acceptable accuracy at short lead times and with minimal need for the costly die try out, using finite element (FE) analyses of hot sheet metal forming in the titanium alloy Ti-6Al-4V. A rather straightforward and inexpensive approach of material modelling and methods for material characterisation are chosen, suitable for early evaluations in the concept phase. Numerical predictions of punch force, draw-in and shape deviation are compared with data from separate forming experiments performed at moderately elevated temperatures. The computed responses show promising agreement with experimental measurements and the predicted shape deviation is within the sheet thickness when applying an anisotropic yield criterion. Solutions for the hot forming tool concept regarding heating and regulation, insulation, blank holding and tool material selection are evaluated within the present work.