- The document analyzes reducing the steps of a deep drawing process for an axisymmetric part from 10 steps to 6 steps using finite element analysis, optimization, and knowledge-based design rules.
- A combination of inverse analysis, optimization, and forward simulation is used to reduce the initial 7-step forming of Zone I to 4 steps, and the final 3 steps are consolidated into 2 steps.
- Comparisons of formability using a damage model and required press loads show the new 6-step process has a lower maximum void volume fraction and slightly higher required press load than the original 10-step process.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
This document reviews optimization of process parameters for surface roughness and material removal rate (MRR) when machining stainless steel 316 on a CNC machine. It begins with an abstract that describes using design of experiments and grey relational analysis to optimize surface roughness based on data from 27 specimens produced via straight turning. The introduction provides background on the importance of surface roughness and challenges of achieving desired quality features on CNC machines. The literature review summarizes several previous studies on optimizing parameters like speed, feed rate, and depth of cut to minimize surface roughness and maximize MRR using techniques like Taguchi methods. The document aims to identify optimal parameter combinations to simultaneously optimize multiple quality objectives.
Investigations of machining parameters on surface roughness in cnc milling u...Alexander Decker
This document summarizes a study that investigated the effect of machining parameters on surface roughness in CNC milling of H-13 die steel using the Taguchi technique. The parameters examined were spindle speed, feed rate, and depth of cut. Experiments were conducted using an L9 orthogonal array. Surface roughness measurements showed that lower feed rates, higher spindle speeds, and greater depths of cut produced lower surface roughness values. Analysis of variance identified feed rate as the most influential parameter on surface roughness. The optimized parameters determined were a low feed rate of 0.08 mm/tooth, high spindle speed of 358.8 RPM, and high depth of cut of 0.3 mm.
This document discusses metal flow simulation and design of dies for close forging. It provides an introduction to simulation and modeling of metal forging processes using finite element analysis. It describes the process modeling inputs such as geometric parameters, material properties, interface conditions, and flow chart for modeling close die forging. The document presents results from simulations run with varying die and workpiece dimensions. It discusses advantages of simulation in reducing costs and time in product development as well as limitations such as inability to model non-axisymmetric geometries and temperature effects. Future work areas include cavity filling prediction and temperature rise prediction to optimize the forging process.
Analysis and optimization of machining process parametersAlexander Decker
This document analyzes machining process parameters like feed, cutting speed, and depth of cut to optimize surface roughness and metal removal rate when turning aluminum alloy and resin workpieces. Experiments were conducted using a response surface methodology. Mathematical models were developed relating the output responses to the input parameters. The models were found to accurately predict the surface roughness and metal removal rate. Optimization found the minimum surface roughness was 1.18 μm for aluminum alloy and 2.295 μm for resin, while the maximum metal removal rate was achieved at higher speeds, feeds, and depths of cut.
Iaetsd experimental investigation and predictive modelling for surface roughn...Iaetsd Iaetsd
This document discusses an experimental investigation into modeling surface roughness when drilling glass fiber reinforced plastic (GFRP) composites. A full factorial design of experiments was used to test the effects of cutting speed, feed rate, and plate thickness on surface roughness. Analysis of variance showed that feed rate had the largest effect on surface roughness. A second-order mathematical model was developed to predict surface roughness based on the cutting parameters. Additionally, a fuzzy logic model was created and validated the predictions of the mathematical model. The goal of the study was to determine optimal drilling parameters to minimize surface roughness of holes in GFRP composites.
Application of taguchi method in the optimization of boring parameters 2IAEME Publication
1. The document describes using the Taguchi method to optimize boring parameters, including cutting speed, feed rate, and depth of cut, to minimize surface roughness.
2. An experiment was conducted using an L27 orthogonal array with 3 factors at 3 levels each, for a total of 27 experiments. Signal-to-noise ratios and analysis of variance were used to analyze the results.
3. The experimental results revealed that depth of cut had the most significant effect on surface roughness, followed by feed rate and then cutting speed, within the specified test ranges. The optimal parameter settings were identified as cutting speed at level 2, feed rate at level 3, and depth of cut at level 1.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
This document reviews optimization of process parameters for surface roughness and material removal rate (MRR) when machining stainless steel 316 on a CNC machine. It begins with an abstract that describes using design of experiments and grey relational analysis to optimize surface roughness based on data from 27 specimens produced via straight turning. The introduction provides background on the importance of surface roughness and challenges of achieving desired quality features on CNC machines. The literature review summarizes several previous studies on optimizing parameters like speed, feed rate, and depth of cut to minimize surface roughness and maximize MRR using techniques like Taguchi methods. The document aims to identify optimal parameter combinations to simultaneously optimize multiple quality objectives.
Investigations of machining parameters on surface roughness in cnc milling u...Alexander Decker
This document summarizes a study that investigated the effect of machining parameters on surface roughness in CNC milling of H-13 die steel using the Taguchi technique. The parameters examined were spindle speed, feed rate, and depth of cut. Experiments were conducted using an L9 orthogonal array. Surface roughness measurements showed that lower feed rates, higher spindle speeds, and greater depths of cut produced lower surface roughness values. Analysis of variance identified feed rate as the most influential parameter on surface roughness. The optimized parameters determined were a low feed rate of 0.08 mm/tooth, high spindle speed of 358.8 RPM, and high depth of cut of 0.3 mm.
This document discusses metal flow simulation and design of dies for close forging. It provides an introduction to simulation and modeling of metal forging processes using finite element analysis. It describes the process modeling inputs such as geometric parameters, material properties, interface conditions, and flow chart for modeling close die forging. The document presents results from simulations run with varying die and workpiece dimensions. It discusses advantages of simulation in reducing costs and time in product development as well as limitations such as inability to model non-axisymmetric geometries and temperature effects. Future work areas include cavity filling prediction and temperature rise prediction to optimize the forging process.
Analysis and optimization of machining process parametersAlexander Decker
This document analyzes machining process parameters like feed, cutting speed, and depth of cut to optimize surface roughness and metal removal rate when turning aluminum alloy and resin workpieces. Experiments were conducted using a response surface methodology. Mathematical models were developed relating the output responses to the input parameters. The models were found to accurately predict the surface roughness and metal removal rate. Optimization found the minimum surface roughness was 1.18 μm for aluminum alloy and 2.295 μm for resin, while the maximum metal removal rate was achieved at higher speeds, feeds, and depths of cut.
Iaetsd experimental investigation and predictive modelling for surface roughn...Iaetsd Iaetsd
This document discusses an experimental investigation into modeling surface roughness when drilling glass fiber reinforced plastic (GFRP) composites. A full factorial design of experiments was used to test the effects of cutting speed, feed rate, and plate thickness on surface roughness. Analysis of variance showed that feed rate had the largest effect on surface roughness. A second-order mathematical model was developed to predict surface roughness based on the cutting parameters. Additionally, a fuzzy logic model was created and validated the predictions of the mathematical model. The goal of the study was to determine optimal drilling parameters to minimize surface roughness of holes in GFRP composites.
Application of taguchi method in the optimization of boring parameters 2IAEME Publication
1. The document describes using the Taguchi method to optimize boring parameters, including cutting speed, feed rate, and depth of cut, to minimize surface roughness.
2. An experiment was conducted using an L27 orthogonal array with 3 factors at 3 levels each, for a total of 27 experiments. Signal-to-noise ratios and analysis of variance were used to analyze the results.
3. The experimental results revealed that depth of cut had the most significant effect on surface roughness, followed by feed rate and then cutting speed, within the specified test ranges. The optimal parameter settings were identified as cutting speed at level 2, feed rate at level 3, and depth of cut at level 1.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Prediction of Draw Ratio in Deep Drawing through Software Simulationsirjes
Deep drawing process is one of the most commonly used Metal Forming Process within the
industrial field. Different analytical, numerical, empirical and experimental methods have been developed in
order to analyze it. In this paper deep drawing process with varying punch and die geometries are analysed. This
work reports on the stages of finite element analysis (FEA) and simulations of a Deep drawing process. The
obtained result allows to find optimum draw ratios in deep drawing.
Process Parametric Optimization of CNC Vertical Milling Machine Using Taguchi...IOSR Journals
Abstract- An experiment was conducted to perform the parametric optimization of CNC end milling machine
tool in varying condition. The tool used for experiment was of Solid Carbide and the Mild Steel work piece was
used during experiment. The experiment has been taken place efficiently and completes its all objective of
optimization. The practical result can be used in industry to get the desirable Surface Roughness and Material
Removal Rate for the work piece by using suitable parameter combination.
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Vibration control of newly designed Tool and Tool-Holder for internal treadi...IJMER
Machining processes are manufacturing methods for ensuring processing quality, usually within
relatively short periods and at low cost. Several machining parameters, such as cutting speed, feed rate, work
piece material, and cutting tool geometry have significant effects on the process quality. Many researchers have
studied the impact of these factors. The cutting tool overhang affects the surface quality, especially during the
internal turning process, but this has not been reviewed much [9].
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document summarizes a study that used the Taguchi method to optimize drilling parameters for minimizing surface roughness when drilling mild steel. Experiments were conducted using an L27 orthogonal array to examine the effects of cutting speed, feed rate, and point angle on surface roughness. Analysis of the experimental results found that the lowest surface roughness was achieved with a low cutting speed, low feed rate, and medium point angle. Feed rate was found to be the most significant factor influencing surface roughness, followed by cutting speed. The optimal combination of drilling parameters to minimize surface roughness in mild steel is a cutting speed of 7 m/min, feed rate of 0.035 mm/rev, and point angle of 90 degrees.
Surface Topology Evaluation of P20 Steel by Multipass Cutting Strategy in Wir...IJERA Editor
Wire EDM process eliminates the work materials by a series of electrical sparks between the workpiece and wire electrode. These sparks creates craters and burs on the machined surface. Machined surface with poor integrity is a major disadvantage of WEDM. This work presents the investigation on multi-pass cutting operation (single rough cut followed by multi trim cuts) in wire electrical discharge machining (WEDM) of p20 steel. Trim cuts were performed using Taguchi’s design of experiment method to investigate the influence of discharge current (Ip), pulse-on time (Ton), pulse-off time, servo voltage and number of trim cuts on two performance characteristics namely cutting rate and surface roughness (SR).Experiments were performed using 0.25mm brass wire. Result shows that the surface finish improves significantly in trim cutting operation.
Simulation of Deep-Drawing Process of Large Panelstheijes
The article deals with the analysis of formability of deep-drawing DC06 steel sheets. The aim of the investigations is to verify possibilities of formability of sheet metal with thickness of 0.85 mm. The mechanical parameters of the sheets have been determined in uniaxial tensile and bulge tests. The numerical simulations using AUTOFORM has been carried out for two drawpiece models. Obtained results can be used during the simulation of real forming process.
Turning parameters optimization for surface roughness by taguchi methodIAEME Publication
This document summarizes a study that used the Taguchi method to optimize surface roughness in a turning operation of cast iron. Experiments were conducted using an L27 orthogonal array to investigate the effects of cutting speed, feed rate, and depth of cut on surface roughness. The results showed that cutting speed had the most significant effect on surface roughness, followed by feed rate and then depth of cut. Based on the analysis, the optimum cutting parameters to minimize surface roughness were determined to be a cutting speed of 1560 rpm, feed rate of 0.16 mm/rev, and depth of cut of 0.5 mm.
Optimization of Process Parameters for CNC Turning using Taguchi Methods for ...IRJET Journal
The document summarizes an experiment that optimized process parameters for CNC turning of EN8 alloy steel using coated and uncoated tool inserts. The experiment used Taguchi methods to design the experiment with three factors (spindle speed, feed rate, and depth of cut) at three levels each in an L9 orthogonal array. The experiments were conducted and measured the responses of surface roughness and material removal rate. Analysis of variance (ANOVA) and Grey relational analysis were then used to analyze the results and determine the optimal process parameters for minimizing surface roughness and maximizing material removal rate.
ANALYSIS OF PROCESS PARAMETERS IN MILLING OF GLASS FIBRE REINFORCED PLASTIC C...IAEME Publication
Milling is one of the most important machining processes in manufacturing parts made out
of FRPs. Milling is a very versatile process capable of producing simple two dimensional flat
shapes to complex three dimensional interlaced surface configurations, in which a rotating,
multi-tooth cutter removes material while traveling along various axes with respect to the work
piece. However, unlike the milling of metals which is characterized by high material removal
rates, milling of FRPs is conducted at much lower scale. The reason for this is that FRP
components are largely made near net shape and any subsequent milling is limited mainly tode-burring and trimming as well as to achieving contourshapeaccuracy. Milling compositematerials are significantly affected by the tendency of these materials to delaminate under the
action of machining forces, cutting force, feed force and depth force respectively.Quality surface milling of Glass Fibre reinforced Plastic materials present variety ofissues, such milling is one of the foremost oftentimes used material removal processes in
machining of FRPs to produce a well-defined surface finish and has surface delaminationrelated to the characteristics of the material and therefore the cutting parameters used. Thesurface quality and dimensional precision greatly have an effect on the elements throughout
their useful life, especially in cases wherever the elements come in contact with differentelements or materials. Optimization of machining parameters is a necessary step in machining.
This project presents a new approach for optimizing the machining parameters on end millingof glass-fibre reinforced plastic composites. Optimization of machining parameters was doneby Taguchi method in milling experiments were conducted for Glass fibre reinforced plastic
composite plates using solid carbide end mills with various helix angles. The parameters ofmachining such as, Fibre orientation angle, spindle speed, feed rate and helix angle are
Analysis of Process Parameters in Milling of Glass Fibre Reinforced Plastic Composites
http://www.iaeme.com/IJMET/index.asp 150 editor@iaeme.com
optimized by multi-response concerns particularly surface roughness and machining force the
optimum levels of parameters have been investigated by using Taguchi method.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
IRJET- ANN Modeling for Prediction of Cutting Force Component during Orthogon...IRJET Journal
This document describes research using an artificial neural network model to predict cutting force during orthogonal turning. The researchers developed a MATLAB interface to estimate the effects of cutting parameters like speed, feed rate, and depth of cut on cutting force. They conducted turning experiments on mild steel and measured cutting forces. This experimental data was used to train an ANN model with cutting parameters as inputs and measured cutting forces as outputs. The trained ANN model could then predict cutting forces based on given cutting parameter values, providing a way to estimate experimental results without additional physical tests. Evaluation showed the ANN model provided precise predictions of how cutting parameters influence cutting force.
Formability of superplastic deep drawing process with moving blank holder for...eSAT Journals
Abstract In this present work, a statistical approach based on Taguchi Techniques and finite element analysis were adopted to determine the formability of conical cup using warm deep drawing process. The process parameters were temperature, coefficient of fric-tion, strain rate and blank holder velocity. The experimental results were validated using a finite element software namely D-FORM. The AA1050–H18 sheets were used for the superplastic deep drawing of the conical cups. The strain rate by itself has a significant effect on the effective stress and the height of the conical cup drawn. The formability of the conical cups was outstand-ing for the surface expansion ratio greater than 2.0.
Keywords: AA1050-H18, superplastic deep drawing, blank holder velocity, temperature, coefficient of friction, strain rate, conical cups, formability.
Analysis of Process Parameters in Dry Turning of Medium Carbon Steel En19 by ...IJERA Editor
This document presents an analysis of surface roughness characteristics during dry turning of medium carbon steel EN19. Experiments were conducted using a Taguchi L9 orthogonal array to evaluate the effects of cutting speed, feed rate, and depth of cut on the surface roughness parameters Ra, Rq, and Rz. Grey relational analysis was used to determine the optimal process parameters that minimize all response variables. Regression models were developed to predict the surface roughness, which showed high correlation. Cutting speed was found to have the greatest influence on surface roughness based on ANOVA analysis.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
This document discusses using the Taguchi method to optimize injection moulding process parameters to minimize shrinkage when molding low density polyethylene (LDPE). An experiment was conducted using an L9 orthogonal array to test different levels of melting temperature, injection pressure, refilling pressure, and cooling time. The results showed that cooling time had the greatest influence on shrinkage, followed by refilling pressure, with injection pressure having the least effect. Analysis of the signal-to-noise ratios identified an optimal parameter combination of 190°C melting temperature, 55MPa injection pressure, 85MPa refilling pressure, and 11 seconds cooling time which produced the lowest shrinkage for LDPE.
IRJET- Experimental Study of Taguchi Vs GRA Parameters During CNC Boring in S...IRJET Journal
This document describes an experimental study comparing the Taguchi method and Grey Relational Analysis (GRA) parameters for CNC boring of steel plate SS-304. Nine experiments were designed using Taguchi's L9 orthogonal array to evaluate the effects of cutting speed, feed rate, and depth of cut on material removal rate (MRR) and surface roughness (Ra). The experiments were conducted on a CNC lathe and the responses measured. Taguchi analysis and GRA were used to analyze the data and determine the optimal cutting conditions for maximizing MRR and minimizing Ra. The Taguchi method predicted an optimal MRR of 29.233 mm3/min at 110 rpm, 0.08 mm/min feed, and 1.
A Study on Thermo-Mechanical Analysis of Hot Rolling & Estimation of Residual...IOSR Journals
The major problem in rolling process is the defects like fire cracks, severe sticking in a billet mill,
and etc. This paper deals with the study on reducing or minimizing the defects of rolling process. The analysis
has been carried out for different temperature i.e. 100°c, 150°c, 200°c, 250°c. As the temperature goes on
increasing correspondingly the residual stresses decreases. Hot rolling process helps in reduced residual
stresses at high temperature & helps in formation of smooth granular structure of product. Due to the symmetry
of the rolling components, half the model is built & the analysis is carried out with 4 roller sizes varying from
8mm to 20mm with 4mm increment & the results were tabulated by using ANSYS. This will helps in estimation
of residual stresses.
Taguchi Method for Optimization of Cutting Parameters in Turning OperationsIDES Editor
Surface roughness an indicator of surface quality is
one of the prime customer requirements for machined parts.
For efficient use of machine tools, optimum cutting
parameters are required. The turning process parameter
optimization is highly complex and time consuming. In this
paper taguchi parameter optimization methodology is applied
to optimize cutting parameters in turning. The turning
parameters evaluated are, cutting velocity, feed rate, depth of
cut, and nose radius of tool and hardness of the material each
at two levels. The results of analysis show that feed rate,
cutting velocity and nose radius have present significant
contribution on the surface roughness and depth of cut and
hardness of material have less significant contribution on the
surface roughness.
Dokumen tersebut berisi hasil analisis organoleptis, kelarutan, pengarangan, reaksi gugus, reaksi golongan, dan reaksi individu dari beberapa zat uji. Zat-zat uji tersebut meliputi benzokaina dan satu zat lain yang bentuknya serbuk berwarna putih kecoklatan. Beberapa reaksi kunci yang diuraikan meliputi reaksi diazo, reaksi iodoform, reaksi indofenol, dan reaksi kuprifil.
Prediction of Draw Ratio in Deep Drawing through Software Simulationsirjes
Deep drawing process is one of the most commonly used Metal Forming Process within the
industrial field. Different analytical, numerical, empirical and experimental methods have been developed in
order to analyze it. In this paper deep drawing process with varying punch and die geometries are analysed. This
work reports on the stages of finite element analysis (FEA) and simulations of a Deep drawing process. The
obtained result allows to find optimum draw ratios in deep drawing.
Process Parametric Optimization of CNC Vertical Milling Machine Using Taguchi...IOSR Journals
Abstract- An experiment was conducted to perform the parametric optimization of CNC end milling machine
tool in varying condition. The tool used for experiment was of Solid Carbide and the Mild Steel work piece was
used during experiment. The experiment has been taken place efficiently and completes its all objective of
optimization. The practical result can be used in industry to get the desirable Surface Roughness and Material
Removal Rate for the work piece by using suitable parameter combination.
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Vibration control of newly designed Tool and Tool-Holder for internal treadi...IJMER
Machining processes are manufacturing methods for ensuring processing quality, usually within
relatively short periods and at low cost. Several machining parameters, such as cutting speed, feed rate, work
piece material, and cutting tool geometry have significant effects on the process quality. Many researchers have
studied the impact of these factors. The cutting tool overhang affects the surface quality, especially during the
internal turning process, but this has not been reviewed much [9].
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document summarizes a study that used the Taguchi method to optimize drilling parameters for minimizing surface roughness when drilling mild steel. Experiments were conducted using an L27 orthogonal array to examine the effects of cutting speed, feed rate, and point angle on surface roughness. Analysis of the experimental results found that the lowest surface roughness was achieved with a low cutting speed, low feed rate, and medium point angle. Feed rate was found to be the most significant factor influencing surface roughness, followed by cutting speed. The optimal combination of drilling parameters to minimize surface roughness in mild steel is a cutting speed of 7 m/min, feed rate of 0.035 mm/rev, and point angle of 90 degrees.
Surface Topology Evaluation of P20 Steel by Multipass Cutting Strategy in Wir...IJERA Editor
Wire EDM process eliminates the work materials by a series of electrical sparks between the workpiece and wire electrode. These sparks creates craters and burs on the machined surface. Machined surface with poor integrity is a major disadvantage of WEDM. This work presents the investigation on multi-pass cutting operation (single rough cut followed by multi trim cuts) in wire electrical discharge machining (WEDM) of p20 steel. Trim cuts were performed using Taguchi’s design of experiment method to investigate the influence of discharge current (Ip), pulse-on time (Ton), pulse-off time, servo voltage and number of trim cuts on two performance characteristics namely cutting rate and surface roughness (SR).Experiments were performed using 0.25mm brass wire. Result shows that the surface finish improves significantly in trim cutting operation.
Simulation of Deep-Drawing Process of Large Panelstheijes
The article deals with the analysis of formability of deep-drawing DC06 steel sheets. The aim of the investigations is to verify possibilities of formability of sheet metal with thickness of 0.85 mm. The mechanical parameters of the sheets have been determined in uniaxial tensile and bulge tests. The numerical simulations using AUTOFORM has been carried out for two drawpiece models. Obtained results can be used during the simulation of real forming process.
Turning parameters optimization for surface roughness by taguchi methodIAEME Publication
This document summarizes a study that used the Taguchi method to optimize surface roughness in a turning operation of cast iron. Experiments were conducted using an L27 orthogonal array to investigate the effects of cutting speed, feed rate, and depth of cut on surface roughness. The results showed that cutting speed had the most significant effect on surface roughness, followed by feed rate and then depth of cut. Based on the analysis, the optimum cutting parameters to minimize surface roughness were determined to be a cutting speed of 1560 rpm, feed rate of 0.16 mm/rev, and depth of cut of 0.5 mm.
Optimization of Process Parameters for CNC Turning using Taguchi Methods for ...IRJET Journal
The document summarizes an experiment that optimized process parameters for CNC turning of EN8 alloy steel using coated and uncoated tool inserts. The experiment used Taguchi methods to design the experiment with three factors (spindle speed, feed rate, and depth of cut) at three levels each in an L9 orthogonal array. The experiments were conducted and measured the responses of surface roughness and material removal rate. Analysis of variance (ANOVA) and Grey relational analysis were then used to analyze the results and determine the optimal process parameters for minimizing surface roughness and maximizing material removal rate.
ANALYSIS OF PROCESS PARAMETERS IN MILLING OF GLASS FIBRE REINFORCED PLASTIC C...IAEME Publication
Milling is one of the most important machining processes in manufacturing parts made out
of FRPs. Milling is a very versatile process capable of producing simple two dimensional flat
shapes to complex three dimensional interlaced surface configurations, in which a rotating,
multi-tooth cutter removes material while traveling along various axes with respect to the work
piece. However, unlike the milling of metals which is characterized by high material removal
rates, milling of FRPs is conducted at much lower scale. The reason for this is that FRP
components are largely made near net shape and any subsequent milling is limited mainly tode-burring and trimming as well as to achieving contourshapeaccuracy. Milling compositematerials are significantly affected by the tendency of these materials to delaminate under the
action of machining forces, cutting force, feed force and depth force respectively.Quality surface milling of Glass Fibre reinforced Plastic materials present variety ofissues, such milling is one of the foremost oftentimes used material removal processes in
machining of FRPs to produce a well-defined surface finish and has surface delaminationrelated to the characteristics of the material and therefore the cutting parameters used. Thesurface quality and dimensional precision greatly have an effect on the elements throughout
their useful life, especially in cases wherever the elements come in contact with differentelements or materials. Optimization of machining parameters is a necessary step in machining.
This project presents a new approach for optimizing the machining parameters on end millingof glass-fibre reinforced plastic composites. Optimization of machining parameters was doneby Taguchi method in milling experiments were conducted for Glass fibre reinforced plastic
composite plates using solid carbide end mills with various helix angles. The parameters ofmachining such as, Fibre orientation angle, spindle speed, feed rate and helix angle are
Analysis of Process Parameters in Milling of Glass Fibre Reinforced Plastic Composites
http://www.iaeme.com/IJMET/index.asp 150 editor@iaeme.com
optimized by multi-response concerns particularly surface roughness and machining force the
optimum levels of parameters have been investigated by using Taguchi method.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
IRJET- ANN Modeling for Prediction of Cutting Force Component during Orthogon...IRJET Journal
This document describes research using an artificial neural network model to predict cutting force during orthogonal turning. The researchers developed a MATLAB interface to estimate the effects of cutting parameters like speed, feed rate, and depth of cut on cutting force. They conducted turning experiments on mild steel and measured cutting forces. This experimental data was used to train an ANN model with cutting parameters as inputs and measured cutting forces as outputs. The trained ANN model could then predict cutting forces based on given cutting parameter values, providing a way to estimate experimental results without additional physical tests. Evaluation showed the ANN model provided precise predictions of how cutting parameters influence cutting force.
Formability of superplastic deep drawing process with moving blank holder for...eSAT Journals
Abstract In this present work, a statistical approach based on Taguchi Techniques and finite element analysis were adopted to determine the formability of conical cup using warm deep drawing process. The process parameters were temperature, coefficient of fric-tion, strain rate and blank holder velocity. The experimental results were validated using a finite element software namely D-FORM. The AA1050–H18 sheets were used for the superplastic deep drawing of the conical cups. The strain rate by itself has a significant effect on the effective stress and the height of the conical cup drawn. The formability of the conical cups was outstand-ing for the surface expansion ratio greater than 2.0.
Keywords: AA1050-H18, superplastic deep drawing, blank holder velocity, temperature, coefficient of friction, strain rate, conical cups, formability.
Analysis of Process Parameters in Dry Turning of Medium Carbon Steel En19 by ...IJERA Editor
This document presents an analysis of surface roughness characteristics during dry turning of medium carbon steel EN19. Experiments were conducted using a Taguchi L9 orthogonal array to evaluate the effects of cutting speed, feed rate, and depth of cut on the surface roughness parameters Ra, Rq, and Rz. Grey relational analysis was used to determine the optimal process parameters that minimize all response variables. Regression models were developed to predict the surface roughness, which showed high correlation. Cutting speed was found to have the greatest influence on surface roughness based on ANOVA analysis.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
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Taguchi Method for Optimization of Cutting Parameters in Turning OperationsIDES Editor
Surface roughness an indicator of surface quality is
one of the prime customer requirements for machined parts.
For efficient use of machine tools, optimum cutting
parameters are required. The turning process parameter
optimization is highly complex and time consuming. In this
paper taguchi parameter optimization methodology is applied
to optimize cutting parameters in turning. The turning
parameters evaluated are, cutting velocity, feed rate, depth of
cut, and nose radius of tool and hardness of the material each
at two levels. The results of analysis show that feed rate,
cutting velocity and nose radius have present significant
contribution on the surface roughness and depth of cut and
hardness of material have less significant contribution on the
surface roughness.
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Surface roughness has significant effect on functionality and service life of components. If surface roughness is properly controlled then, performance of the component enhances in operational applications. Surface roughness becomes key concern when intricate profiles and shapes are required to be manufactured in components. The objective of the paper is to bring up an adequate surface roughness in finish cut by optimizing process variables. If initial surface form is obtained by proper control of machining parameters then additional finishing efforts and lead time reduce a lot. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of process parameters is essential in order to arrest surface roughness and thereby improve surface textures. Experimental investigations are performed to study the effect of pulse current, pulse on time and gap voltage on response of surface roughness, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining
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1. Analysis of an Axisymmetric Deep Drawn Part Forming
Using Reduced Forming Steps
Jian Cao, Shunping Li
Department of Mechanical Engineering
Northwestern University
Evanston, IL 60208-3111
Tel: 847-467-1032
Fax: 847-491-3915
Email: jcao@northwestern.edu
Z. Cedric Xia and Sing C. Tang
MD 3135
FORD Scientific Research Laboratory
Dearborn, MI 48121
Submitted to the Journal of Materials Processing Technology
ABSTRACT
Numerical simulations have been widely used to assist part and process design. In this paper,
deep drawing processes of an axisymmetric part with a complex geometry are analyzed with the
aim of reducing possible forming steps. The existing practice requires 10-step drawing. Our
approach combines optimization scheme, design rules and numerical tests using finite element
analysis incorporated with a damage model. As a result, the 10-step drawing is reduced to 6-step
drawing. Additionally, the new process design yields a lower maximum void volume fraction in
the sheet, meaning a more formable process, and a slightly higher press load.
1
2. INTRODUCTION
Sheet metal forming possesses great design flexibility, high productivity and the ability to offer
high strength and lightweight products. Multi-step drawing processes are usually applied to
forming parts that have geometrical complexity or formability problem and cannot be formed by
one-step forming. In these cases, one of the most critical and challenging issues is to determine
minimum required forming steps and the corresponding tooling shapes as tooling cost is the
major expense. Design of multi-step drawing process has been heavily relying on experience-
based technology as it is not trivial to systematically analyze the effects of all the design
parameters on the quality of parts drawn.
Recently, sensitivity analysis combined with incremental FEM has been widely studied by many
researchers to automatically identify optimal conditions [1-8]. Badrinarayanan and Zabaras [1]
calculated an optimum die shape of an extrusion problem. Chenot and co-workers [3,4], Zhao
and colleagues [5,6] calculated an intermediate tool shape of two-step forging problems.
Badrinarayanan[1], Chenot [4] and Zhao [6] used 6, 3 and 20 design variables to define a tool
shape, respectively. These works were focused on the design of a single target tool shape with
only a limited number of design variables, whereas multiple tool shapes involve much more
design variables. The multi-step drawing problem needs the determination of the minimum
required forming steps as well as the optimum tool shapes for each step.
Inverse finite element method using the deformation theory has been developed for sheet metal
forming process [9-15] to optimize initial blank shapes and process parameters with the promise
of obtaining reasonable accuracy in a very short time period. Most inverse finite element
methods have been focused on only thin sheet metal forming problem. Recently, Lee and Cao
[15] developed a multi-step inverse method using shell element to solve both thin and thick
metal forming problems with increased accuracy. The change of strain path in a drawing process
and the bending effect were considered, which led to 1% discrepancy in predicting the original
blank diameter and 12% discrepancy in radial strain prediction. The accuracy of these
predictions were considerably improved from the corresponding 5% and 46% discrepancies
when membrane elements were used in one-step inverse analysis. However, no sensitivity
2
3. analysis incorporated with the inverse FEM has been developed to find the optimum tooling
shapes automatically.
Alternatively, knowledge-based system has been explored to design intermediate tooling
conditions and to determine minimum required drawing steps of axisymmetric deep drawing
problems and two-dimensional forging problems [16-19]. The approach has shown some
success, however, it cannot handle the process conditions beyond given knowledge rules. The
knowledge for thick sheet metal drawing has not been systematically documented.
The objective of this paper is to find a new forming process that will reduce forming steps of an
axisymmetric thick metal drawing problem. Systematic approach, which consists of finite
element code with sensitivity analysis, optimization method, damage model for assessing failure
potential and knowledge rules, are being investigated here to find an optimum condition. Side
by side comparisons of formability and press load will be presented to demonstrate the feasibility
of the approach.
PROBLEM DESCRIPTION
An automotive part illustrated in Fig.1 has an axisymmetric shape and was formed by a 10-step
drawing process due to difficulties in forming Zone I with an initial blank thickness of 5 mm.
This initial blank is thicker than most of common sheet forming products with that dimension.
The final shape after multi-step drawings and springback should satisfy the geometric
requirements as shown in Fig.1 without physical defects.
The material properties of a mild-steel and the initial blank size used in FEM analysis are as
follows:
Stress-strain relation : σ = 533.3 (0.0018 + ε )0.1908 MPa
Young’s modulus : E= 210 GPa
Poisson’s ratio : υ= 0.34
Lankford value : r = 1.0
Friction coefficient : µ= 0.1
3
4. Initial blank thickness : to = 5.0 mm
Initial blank diameter : φB = 330 mm
ANALYSIS OF ORIGINAL DRAWING PROCESS
The existing forming process consists of 10 steps, that is, 7-step, 2-step and 1-step drawing to
form Zone I, Zone II and Zone III, respectively. The process was simulated by Finite Element
analysis using a commercial implicit FEM package ABAQUS/Standard to establish the base for
our following analysis. The finite element model in Fig.2a has 8 layers (4 layers in the flat areas)
through the thickness direction, and 140 8-node solid elements with reduced integration
(ABAQUS type CAX8R) along the radial direction. The entire 10-step drawings have been
solved including springback after each drawing step. The initial geometry and deformed shapes
for each step are shown in Fig.2. The distribution of void volume fraction using the Gurson-
Tvergaard damage model associated with the von-Mises yield criterion and the tooling reaction
forces were recorded. These data will be presented later with those of new proposed drawing
processes for comparison.
DETERMINATION OF NEW DRAWING PROCESS
It is worth noticing that the most difficult forming area is in Zone 1 and the first draw is deeper
than the final desired height in order to form the extremely tight radius (R/t=0.24) (see Fig.2l).
The existing process plan requires 7-step drawing to form Zone 1. Here, in this section, we will
utilize a combination of optimization scheme, inverse analysis and forward analysis to reduce the
step number to 4. The 1st step will be the drawing stage to move material to the center region.
The 2nd and 3rd steps are the transition stages. Finally, the 4th step is the shaping stage that makes
the final shape of Zone I. The 8th to 10th steps in the original process will be consolidated to 2
steps, which results in a total of 6-step drawing instead of the original 10-step drawing.
STEP 1
The objective of this forming step is to draw enough material into Zone I for the
subsequent drawing and to have the punch diameter as close as possible to the final dimension.
4
5. The thinning should be kept below a reasonable level (i.e. 20% for steel alloy) so that it would
not cause tearing problems in the following forming steps. Wrinkling is not a major concern in
this problem as the sheet thickness is very thick [20]. Similar to Step 1 in the existing process,
only straight wall tooling with a circular radius is considered. Therefore, possible tooling
variables are the punch diameter, d, the punch profile radius, r1, and the die profile radius, r2,
(see Fig.2b and Fig.6a). The gap between the punch and the die is set to be 2* t0 more than the
punch diameter, where t0 is the initial sheet thickness. The drawing depth is kept to 48mm as
described in Lee et al. [21]1 to avoid collapse in the subsequent forming step. Other process
parameters, including a binder force of 80 KN and a friction coefficient of 0.1 between the
tooling and the blank, are used in this step.
The optimization problem can then be formulated as to find a possible set of ( d , r1, r 2 )
within the design domain R, i.e., ( d , r1, r 2 ) ∈ R , so that the objective function, F,
F(r1,r2,d)= tdiff/t0+0.03(d-df)/df (1)
is minimized, where tdiff is the maximum thickness reduction after forming and df is the final
inner diameter of Zone I in Fig. 1. The factor of 0.03 is determined by test runs to balance the
contributions of two parts in the objective function. It should be pointed out that the formulation
of the objective function is problem dependent and test runs are needed to verify the behavior of
the objective function and the effectiveness of available optimization algorithms.
The design domain of the punch and die profile radii is set to be (2~12)to based on the
experience, whereas the thickness reduction is calculated by the inverse analysis as described in
Lee and Cao [15]. The computation cost is much smaller than the forward incremental FEM
analysis. A typical one step inverse analysis takes less than 15 seconds on a PentiumII 400 PC
for this problem, and reasonable results can be obtained., while a forward analysis using
ABAQUS may take several hours. Therefore, inverse analysis is preferable in optimization
procedure since a large number of simulations are needed to find the minimum of the objective
function. The optimization algorithm used, direction method, is shown in Fig. 3, which searches
each variable direction (using line-search method) within the prescribed range for each iteration
[22]. Although other sophisticated algorithms such as conjugate gradient, BFGS can be used in
1
In that work, the same tooling design problem was attempted using knowledge based design approach.
5
6. the program, the present one provides the best results and performance. It is advisable to try
different algorithms for practical engineering problems and different initial values to test the
effectiveness of an optimization process. The convergence criterion for optimization is as
follows:
|| Xk+1-Xk ||≤ε (2)
where Xk , Xk+1 are the variable vectors before and after one iteration, and ε is the convergence
tolerance, the value of 0.1 is used in this study.
Various initial values in the design domain (r1,r2 = 10~60 mm, d = 100~130 mm) are used
to test the robustness of the algorithm and very close values are obtained as shown in Table 1.
The final optimized punch and die parameters are:
r1=30.00mm r2=60.00mm d=117.60mm
The total computation time to finish this particular optimization was less than 5 minutes on a
PentiumII 400 PC.
STEPS 2 AND 3
Inverse analysis is very efficient in designing the first draw as shown above. However, it
has not been able to handle a non-flat initial blank shape. This limitation prevents us from using
the same approach developed above to design following forming steps. Instead, knowledge-
based design approach will be used.
• Basic Design Rules of Steps 2 and 3
! At the end of steps 2 and 3, the center region should be drawn to an adequate height.
Shallow height can cause necking problem at step 4 and severe depth can yield high
tooling pressure and folding problem since the excessive material needs to be shrunk to
the final geometry.
! At the end of steps 2 and 3, the diameter of wall region should be as close to the final
specification as possible while the thickness reduction of this region should be as small as
possible.
6
7. • Feasible Process Conditions of Step 2
- The feasible die shape is shown in Fig.4(a). The straight slant-line shape is used to force
the material more close to the final geometry than that the tooling used in [21]. This helps
to relieve the excessive bending at the punch corner in the following forming step.
• Feasible Process Conditions of Step 3
! The die shape of step 3 is similar to that of step 4.
! - The die diameter and radius of step 3 should be smaller than those of step 2 and should
be larger than those of step 4. Die Diameter=32mm
! ABAQUS analyses have been performed using the above die shapes of step 3 and the
best feasible tooling conditions of steps 1 and 2 until 4th step forming. The major problem
in step 3 is the excessive bending at the final stage of forming when the material at the
punch corner are forced to bend severely. A solution to this problem is to change the die
shape in Fig.2e to that shown in Fig.4b. The slanted part in the proposed punch profile
serves the purpose of forcing more material down to the die shape.
STEP 4
The tooling shapes of step 4 can be obtained from the deformed shape of Fig.1. The
13mm die radius leads to a folding problem at the end of step 4 as shown in Fig5(a). The 15mm
die radius has the same problem with less folding. Under the same process conditions of steps 1,
2 and 4, 17mm die radius of step 3 provides the best results with no folding.
In the modification procedure, the entire 6-step drawing processes were solved to find a
better condition by small modifications. For example, the tool movements of step 5 were
modified to compensate springback effect of the final product. Springback in these forming
processes was not significant due to the usage of thick blank and the axisymmetric geometry.
The amount of springback in the Z direction was 1.25 mm for region A and 0.35 mm for region
B of Fig. 6g. These amounts of springback were simply added to the tool movements of step 5.
The blank size could be modified after the analysis of all the steps considering the height of Zone
III. As a result, a new reduced forming process is found and the deformed shapes of each step are
shown in Fig.6. The final deformed shape of Fig. 6g satisfies the geometric requirement of Fig.1
7
8. within the tolerance limit. The formability of this sequence needs to be examined and will be
presented below.
COMPARISON BETWEEN THE ORIGINAL AND PROPOSED PROCESSES
FORMABILITY
During the forming processes, the possible failure modes can be classified as necking,
folding and wrinkling. In this application, wrinkling is not of our concern due to the usage of a
very thick blank. The folding problem could occur in the case of inappropriate combination of
tooling conditions and this problem can be easily detected by examining the deformed shapes.
Consequently, necking and subsequent ductile fracture are the major challenges for a successful
design. In order to avoid these kinds of phenomena, the Gurson-Tvergaard damage model
[23,24] is applied in the present work to examine the formability. Based on the experimental
observation, the micro-scale defects in the form of voids is taken into account and considered as
damage. The voids nucleation, growth, and coalescence determine the failure process during
metal deformation. Thus, the volume fraction of voids works as a damage parameter in the
constitutive relation derived with this damage model. The yield surface of Gurson-Tvergaard
damage model based on von-Mises material is defined by
2
σ eq
Φ =
σy 2σ y
( )
+ 2q 1 f cosh q 2 3σ m − 1 + q 3 f 2 = 0
where σeq, σy, σm are the equivalent, yield and hydrostatic stresses, respectively. f is the void
volume fraction and q1 , q2 and q3 are material parameters. The initial void volume faction was
assumed 0.005. q1, q2 were assumed 1.5 and 1 respectively. q3 is equal to q 12 .
In order to evaluate the possible failure during the forming analysis, ABAQUS analysis with the
damage model has been performed. Fig.7 shows the distributions of void volume fraction
obtained from the original (10-step) and proposed (6-step) processes. Two comparisons are
presented here. One corresponds to the most severe forming stage, that is, after the 4th step in the
original process (see Fig.7a) and the 3rd step in the new process (see Fig.7b). The other
comparison is at the end of all the forming steps. It can be seen that the maximum void volume
8
9. fractions in the new process are lower than those in the original process in both cases, 0.0896 (3rd
step new) vs. 0.0928 (4th step old) and 0.0952 (final, new) vs. 0.0998 (final, old). These results
imply that the designed forming procedure is not beyond the allowance from the formability of
the metal.
PRESS LOAD
The forming load in each of the forming step is monitored in the simulations and presented in
Fig.8. The total press load is plotted against the increment numbers in the simulation as no
effective normalization can be found. Notice that the high peaks of the load curve is due to the
striking of the moving punch/die on the blank at the final forming stage. In practical forming,
this should be avoided by adjusting the tooling movement.
SUMMARY
A reduced multi-step drawing process has been designed using a combined approach of
optimization method, inverse FEM analysis and forward finite element analysis. Inverse FEM
and optimization method were used for the tooling design of first draw. Additional design rules
for subsequent drawing steps were useful to construct new tooling shapes. The maximum void
volume fraction in the new process, a measurement of tearing potential, is about 5% lower than
that in the original one, while the press loads are almost identical. These numbers indicate that
the proposed new approach is a valid alternative design.
ACKNOWLEDGEMENT
The support from Ford Motor Company is gratefully acknowledged.
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11. pp.76-82.
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11
12. Table 1: Results of optimization using various initial guesses.
Initial Value(mm) Final Value(mm)
r1 r2 d r1 r2 d
33.0 28.5 110.0 30.0 60.0 117.6
30.0 37.5 110.0 27.6 60.0 114.0
18.0 28.5 98.0 27.3 60.0 114.0
18.0 51.0 126. 28.2 60.0 113.9
12
13. Z
df = φ 14.25
( Unit : mm )
3.05
24.15
12.15
R
φ 122.70
31.5
φ 160.50
φ 265.75
Zone I Zone II Zone III
Fig.1 An automotive part of axisymmetric shape formed by multi-step drawing.
13
14. 5mm
165 mm
(g) Step 6
(a) Initial Mesh
Φ143.96
r2=49.83
44.296
(h) Step 7
r1=34.29
d=Φ143.1
(b) Step 1
(i) Step 8
(c) Step 2
(j) Step 9
(d) Step 3
(k) Step 10
(e) Step 4
R= 1.2
(l) Final Shape
(f) Step 5
Unit: mm
Fig.2 Initial geometry and deformed shapes for each drawing step in the original process.
14
15. Give initial values X0
Search every direction
(number of variables) to
minimize F
X0=X No
||X-X0||<ε?
Yes
Output results
Fig.3 Optimization algorithm used in determining the tooling shape of Step 1.
φ32 φ26
60°
R17
21
30°
(a) Step2 (b) Step 3
Fig. 4 New tooling geometries of steps 2 and 3.
15
16. (a)
(b)
Fig.5 Comparison of deformed shapes at the end of step 4 with different die radii of step 3:
(a) Die radius = 13mm, (b) Die radius = 17mm.
16
17. Φ127.6
R60
R30
48
Φ117.6
(a) Step 1
Φ32
Φ44
R17.
(b) Step 2 (c) Step 3
Φ26
R3.5
(d) Step 4 (e) Step 5
B
A
(f) Step 6 (g) Final Geometry
Fig.6 Deformed shapes of each drawing step in the new process
17
18. VVF Value VVF Value
1-1.48 E-02 1-1.37 E-02
4 2-3.03 E-02 2-2.89 E-02
3-4.59 E-02 4 3 3-4,41 E-02
3 4-5.93 E-02
4-6.15 E-02
5-7.70 E-02 2 5-7.44 E-02
2 Max= 8.96E-02
1 Max= 9.26E-02
1 Min=-1.48E-03
Min=-7.21E-04
(a) contour of step 4 of old process (b) contour of step 3 of new process
1 2 1
2
3
2
4 1 4
2 3 3
VVF Value 2
4 VVF Value
1—1.31 E-02
1-1.21 E-02
2
2—3.04 E-02 3 1 1 1
3—4.77 E-02 2-2.87 E-02
4—6.51 E-02 3-4,54 E-02
5—8.34 E-02 4-6.20 E-02
Max=9.981E-02 5-7.86 E-02
Min=-4.27E-03 Max= 9.52E-02
Min=-4.53E-03
(c) contour of last step in old process (d) contour of last step in new process.
Figure 7. Distributions of void volume fraction
Forming Load
3.50E+07
3.00E+07 --- Original Process
New Process
2.50E+07
Load/N
2.00E+07
1.50E+07
1.00E+07
5.00E+06
0.00E+00
0 500 1000 1500 2000 2500 3000 3500
Increment Number
Figure 8 Forming Load of new & original processes
18