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A. Mentella ifu-hydro
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A. Mentella ifu-hydro

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    A. Mentella ifu-hydro A. Mentella ifu-hydro Presentation Transcript

    • Italian Design… Why make it simple? When you can make it beautiful…Source: Wikimedia commons Copyright © ESI Group, 2010. All rights reserved.
    • New Potential Applications for Tube and Sheet Hydroforming in Furnishing and Household Hardware Dr. Alessia Mentella, ESI Italy Prof. Matteo Strano, Politecnico di Milano Dr. Martin Skrikerud, ESI Group Fellbach-Stuttgart/Germany May 6th , 2010 Copyright © ESI Group, 2010. All rights reserved. 2
    • About ESIProvider of Virtual Prototyping for the Industrial WorldESI is a world leading software editor for the numerical simulation of prototypeand manufacturing process engineering in applied mechanics. Copyright © ESI Group, 2010. All rights reserved. 3
    • ESI Worldwide Operations More than 30 countries 15 subsidiaries Average Headcount: 750 people Tokyo, JapanParis, France Eschborn, Germany Pilsen, Czech Republic San Diego, CA, USA Beijing, China Copyright © ESI Group, 2010. All rights reserved. 4
    • Selected Customer References Copyright © ESI Group, 2010. All rights reserved. 5
    • AGENDA IntroductionStainless steel in household Aesthetical requirements and hardware geometrical complexity Forming processes with solid tools Cruet stand Vase Sauce pan Fluid forming processes DSHF - Vase THF – Cruet stand Comparison Vase Cruetstand Conclusions Copyright © ESI Group, 2010. All rights reserved. 6
    • INTRODUCTION Stainless Steel Hygienic and ExcellentCorrosion Surface look polished coldresistance surfaces formability Copyright © ESI Group, 2010. All rights reserved. 7
    • FORMING PROCESSES WITH SOLID TOOLS Conventional deep drawingADDITIONAL DRAWING INVERSE DRAWING Copyright © ESI Group, 2010. All rights reserved. 8
    • FORMING PROCESSES WITH SOLID TOOLS ALESSI’s Cruet stand Production cycleInitial blank:AISI 304 diskD=300mmt=0.8mm. 1° deep drawing 2° deep drawing 3° deep drawing 1° trimming global annealing 4° deep drawing 5° deep drawing 2° trimming 5 punch/die set, 2 annealing 3 necking. Total: 8 dies and partial annealing 1° necking 2° necking 3° necking 5 punches. Copyright © ESI Group, 2010. All rights reserved. 9
    • FORMING PROCESSES WITH SOLID TOOLS ALESSI’s “Babyboop” Vase Production CycleInitial blank:2 AISI 304 2Brectangles;428,5mm x 312,5mm 1° deep drawing 2° deep drawingt=1mm for EACH HALF trimming of the borders trimming of the hole JOINING welding of the two halves welding of the bottom Copyright © ESI Group, 2010. All rights reserved. 10
    • TOWARDS FLEXIBILITY Rubber Forming of “Olympia” Saucepan Production cycle1st deep-drawn raugh-hewn 2nd deep-drawn raugh-hewn ending edge trimming. and annealing. and calibrating. formed part (left), polymeric punch (centre), semi-finished part (right) Copyright © ESI Group, 2010. All rights reserved. 11
    • FLUID FORMING PROCESSES Double Sheet Hydroforming Closing Forming Calibrating FlexformingPositioning Forming Relift Copyright © ESI Group, 2010. All rights reserved. 12
    • FLUID FORMING PROCESSES Tube Hydroforming1.The workpiece is 2.The die is closed 3.The fluid fills positioned between the tube cavity the dies4.The tube ends are 5.The tube is formed by 6.The dies open and sealed the increasing pressure the workpiece is and the punch stroke removed Copyright © ESI Group, 2010. All rights reserved. 13
    • Double Sheet Hydroforming FEM Modeling of ALESSI’s “Babyboop” Vase σ(εp)=K(ε0+ εp)n 4-nodes shell elements with 5 integration points throughout the thickness ρ E [GPa] ν K [GPa] ε0 nAISI304 7.8·10E-06 210 0.3 1.1153 0.017 0.336time [ms] 0 6 18 20 P [GPa] 0 0.025 0.035 0.13 Copyright © ESI Group, 2010. All rights reserved. 14
    • Double Sheet HydroformingALESSI’s Vase - RESULTS Copyright © ESI Group, 2010. All rights reserved. 15
    • Tube hydroforming – axial feeding ALESSI’s Cruet stand1. DOUDLE SHEET HYDROFORMING WITH Aesthetical FLEXIBLE MEMBRANE Welding line along the cruetstand axis, for the joining requirements non of the two shells completely fullfilled2. TUBE HYDROFORMING - SELF FEEDING Lenght of the 1° Hydroforming – Annealing – 2°Hydroforming process quite hight The system is complex3. TUBE HYDROFORMING - AXIAL FEEDING but the part is formed in a single operation Copyright © ESI Group, 2010. All rights reserved. 16
    • Tube hydroforming – axial feeding ALESSI’s Cruet stand ρ E [GPa] ν K [GPa] ε0 n AISI304 7.8·10E-06 210 0.3 1.1153 0.017 0.336 time [ms] 0 0.66 1 3 4 5 P [GPa] 0 0.01 0.0135 0.016 0.0161 0.08 time [ms] 0 2 3vel DX [mm/ms] 20 20 0vel SX [mm/ms] 2 2 0 Copyright © ESI Group, 2010. All rights reserved. 17
    • Tube hydroforming – axial feeding ALESSI’s Cruet stand – Induced wrinkling1 24 3 Copyright © ESI Group, 2010. All rights reserved. 18
    • Tube hydroforming – axial feedingALESSI’s Cruet stand – RESULTS Copyright © ESI Group, 2010. All rights reserved. 19
    • COMPARISON - Vase “Babyboop Vase” Conventional DDR DSHF Forming 4 (2 for each half) 1 Annealing 0 0Special operation for 0 0 undercuts solving 3 (initial blank + border + hole) Trimming 2 (border + hole) for each half for each half Welding 2 (two halves + bottom) 2 (two halves + bottom) n° Dies 1 1 Total op. 10 8 20s x 2 (forming) + 25s (forming) + 25s (trimming) + 25s (trimming) +Manufacturing Time 15s (welding of two halves) + 15s (welding of two halves) + 8s (bottom welding) = 88s 8s (bottom welding) = 73s Copyright © ESI Group, 2010. All rights reserved. 20
    • COMPARISON – Cruet stand Tube Hydroforming“Mami Cruetstand” Conventional DDR DSHF Self feeding Active feeding Forming 5 1 3 1 Annealing 1° global - 2° local 0 2 0Special operation for 3 0 0 0 undercuts solving Trimming 3 2 (1 for each half) 1 1 3 (upper ring + bottom 2 (upper ring + 2 (upper ring + Welding 1 (upper ring) + body) bottom) bottom) n° Dies 5 1 1 1 Total op. 14 6 8 4 60s (5 forming) + 25s (forming) + 50s (3 forming) + 14s (1°annealing) + 20s (forming) + 20s (2 trimming) + 20s (2 annealing) + 7s (2°annealing) + 5s (trimming) + 4s (top ring welding)+ 5s (trimming) +Manufacturing Time 30s (3 necking) + 4s (top ring welding)+ 6s (bottom welding) + 4s (top ring welding) + 10s (3 trimming) + 6s (bottom welding) 15s (body welding) 6s (bottom welding) 4s (top ring welding) = 35s = 70s = 85s = 125s Copyright © ESI Group, 2010. All rights reserved. 21
    • CONCLUSIONSAesthetics in manufacturing:In the case studies discussed, the designer’s vision and itsaesthetic dictates have been successfully combined withtechnological requirements: • joints and welding lines are significantly reduced • the production is simplified in terms of number of operation and needed dies • Problems with possible undercuts in deep drawing are eliminated • if the press is available, the costs for the component production could be lower. Copyright © ESI Group, 2010. All rights reserved. 22
    • CONCLUSIONSHydroforming processes, both THF and SHF, can besuccessfully used in fields that is very different from theclassical automotive or aerospaceIt offers a real alternative when paying respect to theaesthetical aspect of the component, instead of resistanceor strength. Source: Wikimedia commons Copyright © ESI Group, 2010. All rights reserved. 23
    • Thank you! Merci! Danke! Join us atMay 19-20 Munich, Germanywww.esi-group.com/globalforum2010 Copyright © ESI Group, 2010. All rights reserved.