INDUSTRIAL DEFINED PROBLEM ONFormability Study of Layered Material Based on Numerical Analysis                            ...
PROBLEM SUMMARY Components press formed from layered or laminatedmetallic materials have wide engineering applications in...
• If bending is considered as one of the metal forming process in  sheet metal forming industries then, the prediction of ...
ANALYTICAL MODEL FOR INTERNAL BENDING  MOMENT AND SPRINGBACK PREDICTIONThe main assumptions made for the presentedanalysis...
Equation for Bending Moment & Spring back  K’ is equal to [(1.1547)^(n+1)] K
Table 1 Effect on Springback for Same material andsame thicknessMaterial Thickness   Yield  Strength    Strain Unloaded   ...
Fig. 1 Effect of yield strength on                                  Springback Radius                    16               ...
Fig. 2 Effect of strength coefficient on                                   Springback Radius                    16        ...
Fig.3 Effect of Strain Hardening Exponent on                       Springback Radius                    16                ...
Table 2 Effect on Springback for same material and thickness change  Material Type                          Yield    Stren...
Fig. 4 Effect of Thickness ratio(t1/t2) on Springback                                            Radius                   ...
Table 3 Effect on Springback for material change and thickness same   Thickness of       Difference Difference Difference ...
Fig. 5 Effect of difference between yield strength on                               Springback Radius                    9...
Fig. 6 Effect of difference between strength                            coefficient on Springback Radius                  ...
Fig. 7 Effect of difference between Strain Hardening                              exponent on Springback Radius           ...
CONCLUSIONHigh value of strength coefficient and yieldstrength with low value of strain hardening exponentresults into ex...
FUTURE WORK      If we derive equation for bending moment andspringback for multi layer strip for V-Bending, it isbecome v...
References[1] A. H. Gandhi and H. K. Raval, “Analytical and empirical modeling of top rollerposition for 3-roller cylindri...
THANK YOU
Formability study of layered material based on numerical analysis
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Formability study of layered material based on numerical analysis

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Formability Study of Layered Material Based on Numerical Analysis

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Formability study of layered material based on numerical analysis

  1. 1. INDUSTRIAL DEFINED PROBLEM ONFormability Study of Layered Material Based on Numerical Analysis Submitted by: Name Roll no: 1. Majiwala Hardik 8436 2. Mistry Vikram 8440 3. Patel Ankur 8453 4. Patel Ashish 8454 Guided by: DR. ANISH H. GANDHI C.k.pithawalla college of engineering and technology, surat.
  2. 2. PROBLEM SUMMARY Components press formed from layered or laminatedmetallic materials have wide engineering applications inaerospace, automobile, electrical, electronic and processindustries. High strength ferrous material are widely used inautomobile and aerospace applications for improvingstrength to weight ratio. Forming of high strength materials is difficult.Formability of high strength ferrous materials can beimproved by applying the layering of the higher formabilitymaterials. But to fabricate the layered/laminated blanks it-self is achallenging issue. Further, metal forming mechanics oflayered or laminated materials is complex to understand &development of analytical models for studying and analyzingthe forming mechanics of such materials is difficult.
  3. 3. • If bending is considered as one of the metal forming process in sheet metal forming industries then, the prediction of springback is most important technical issue. What is Springback ? Condition that occurs when a flat-rolled metal or alloy is cold- worked; upon release of the forming force, the material has a tendency to partially return to its original shape because of the elastic recovery of the material. This is called Springback. Springback is a phenomenon in which the strip unbends itself after forming.
  4. 4. ANALYTICAL MODEL FOR INTERNAL BENDING MOMENT AND SPRINGBACK PREDICTIONThe main assumptions made for the presentedanalysis are as follows;1. The material is homogeneous and has a stablemicrostructure throughout the deformation process.2. R>>t so, the neutral axis lies in the mid-plane.3. Analysis is based on σ = Kεn4. Plate is having the uniform radius of curvature forthe supported length.5. b >> t. So width changes are negligible.
  5. 5. Equation for Bending Moment & Spring back K’ is equal to [(1.1547)^(n+1)] K
  6. 6. Table 1 Effect on Springback for Same material andsame thicknessMaterial Thickness Yield Strength Strain Unloaded Spring Type (t) Strength Coefficien Harden- Radius back (mm) (σy) t(K) ing (Rf) Radius (N/mm2) (N/mm2) exponent (mm) (Rf-R) (2”) (n) (mm) Low (2”) RangeSA - 36 6 250 554 0.21 106.599 6.598963SA – 299 6 290 698 0.17 109.9952 9.995189SA – 515 6 260 665 0.19 108.7196 8.719649SA – 612 6 345 786 0.20 110.0407 10.04066SA - 724 6 515 862 0.14 114.3997 14.39966
  7. 7. Fig. 1 Effect of yield strength on Springback Radius 16 14Springback Radius 12 10 8 6 4 2 0 0 100 200 300 400 500 600 Yield strength
  8. 8. Fig. 2 Effect of strength coefficient on Springback Radius 16 14Springback Radius 12 10 8 6 4 2 0 0 200 400 600 800 1000 Strength coefficient
  9. 9. Fig.3 Effect of Strain Hardening Exponent on Springback Radius 16 14 12Springback Radius 10 8 6 4 2 0 0 0.05 0.1 0.15 0.2 0.25 Strain hardening exponent
  10. 10. Table 2 Effect on Springback for same material and thickness change Material Type Yield Strength Strain Bending Unloaded Spring- Strength Co- Harden- Moment Radius backSA - 36 SA - 724 (σy) efficient ing (N.mm) (Rf) Radius (N/mm2) (K) exponent (mm) (Rf-R) Thickness (N/mm2) (n) (mm) (2”) (2”) t1 t2 Low Range 1 5 250 554 0.21 3576.166 109.4203 9.42031 2 4 290 698 0.17 2415.842 106.1751 6.175052 3 3 260 665 0.19 1737.81 104.3663 4.366285 4 2 345 786 0.20 1542.646 103.857 3.857018 5 1 515 862 0.14 1822.678 104.5893 4.589304
  11. 11. Fig. 4 Effect of Thickness ratio(t1/t2) on Springback Radius 10 9 8Springback Radius 7 6 5 4 3 2 1 0 0 1 2 3 4 5 6 Thickness Ratio
  12. 12. Table 3 Effect on Springback for material change and thickness same Thickness of Difference Difference Difference Bending Un- Spring- Material Between Between Between Moment loaded back (mm) Yield Strength Strain (N.mm) Radius Radius Strength Coefficient Hardening (Rf) (Rf-R) (σy) (K) exponent (mm) (mm)t1 = 5mm t2 = 1mm (N/mm2) (N/mm2) (n) (2”) (2”) Low RangeSA - 724 SA – 612 170 76 0.06 3600.689 109.491 9.49104SA - 724 SA – 515 255 197 0.05 3592.966 109.4688 9.468755SA - 724 SA – 299 225 164 0.03 3604.44 109.5019 9.501866SA - 724 SA - 36 265 308 0.07 3576.166 109.4203 9.42031
  13. 13. Fig. 5 Effect of difference between yield strength on Springback Radius 9.51 9.5 9.49Springback Radius 9.48 9.47 9.46 9.45 9.44 9.43 9.42 9.41 0 50 100 150 200 250 300 difference between yield strength
  14. 14. Fig. 6 Effect of difference between strength coefficient on Springback Radius 9.51 9.5 9.49Springback Radius 9.48 9.47 9.46 9.45 9.44 9.43 9.42 9.41 0 50 100 150 200 250 300 350 Difference between strength coefficient
  15. 15. Fig. 7 Effect of difference between Strain Hardening exponent on Springback Radius 9.51 9.5Springback Radius 9.49 9.48 9.47 9.46 9.45 9.44 9.43 9.42 9.41 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 difference between Strain Hardening
  16. 16. CONCLUSIONHigh value of strength coefficient and yieldstrength with low value of strain hardening exponentresults into extremely high springback.For materials with constant Young’smodulus, springback increases with; (i) increase instrength coefficient, (ii) increase in yield strength and (iii)reduction in strain hardening exponent.Based on the analytical springback analysis, it isconcluded that as an alternative to the materialsdevelopment, layer of the high ductility ferrous steel canbe used for suppressing the springback during forming ofhigh strength or extra high strength ferrous materials.
  17. 17. FUTURE WORK If we derive equation for bending moment andspringback for multi layer strip for V-Bending, it isbecome very complex. It is derive by W.Y.D Yuen [4] So, for study behavior of multi layer strip, we useFinite Element Analysis for further detail study.
  18. 18. References[1] A. H. Gandhi and H. K. Raval, “Analytical and empirical modeling of top rollerposition for 3-roller cylindrical bending of plates and its experimental verification,” J.Mater. Process Technol., vol. 197, no. 1-3, pp. 268-278, 2008.[2] Edward M. Mielnik, Metal Working Science and Engineering, NewYork, USA, McGraw Hill Book Co., 1991.[3] Z. Marciniak, J. L. Duncan, Mechanics of sheet metal forming, Edward ArnoldLtd., London, 1992.[4] W.Y.D. Yuen “A generalized solution for the prediction of springback ir. Laminatedstrip” Port Kemblu Laboratories, BHP Research, Po Box 202, Port Kembla, NSW2505,Australia Received 16 February 1995
  19. 19. THANK YOU

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