Magnesium is nowadays the lighter metal used in structural applications with expressive advantages over steel and aluminum. Due to its low density and high specific strength, magnesium alloys represent a promising alternative, especially for applications in automobile industry, being used in structural components in order to reduce weight and, consequently, improve fuel efficiency. In the recent decades, several researches have been performed in order to improve the use of Mg alloys in forming process since its formability is strongly affected by some conditions as temperature. In this study, a Finite Element Analysis (FEA) is performed to simulate the sheet metal deep drawing process of the magnesium alloy AZ31. The main objective is to evaluate the effect of the blank holder force and friction conditions in the formability by predicting results of springback, thickness distribution and thinning of the sheet metal blank. In total, 54 simulations were performed.
Finite Element Simulation Analysis of Three-Dimensional Cutting Process Based...IJRES Journal
Metal cutting process is a complicated process of plastic deformation and the finite element
method is used to simulate the cutting process. Chip is an important product of the cutting process, it has
important significance to analysis of it's formation process and influence factors in the research of material
processing performance, cutting tool optimization, etc..In this paper, the three-dimensional orthogonal and
oblique cutting models were established based on Johnson-Cook material constitutive models and damage laws.
The formation process of chip was analyzed according to the metal simulation cutting process, the influence of
cutting variables (Cutting depth, Cutting speed, Work piece thickness)on chip was analyzed based on the status
of chip.
Finite Element Simulation of Serrated Chip Formation in High Speed CuttingIJRES Journal
The description of high speed cutting process with simulation based on finite element method provides huge superiorities compared to analytical and experimental models. This work focused on the study of high speed cutting process with finite element method, using commercial software ABAQUS/Explicit. The chip morphology is predicted, and the stress, strain and temperature in the chip are all simulated vividly when cutting stably. The serrated chip formation is explained by the adiabatic shear theory. The results showed that it is better to use the adiabatic shear theory to explain the formation of serrated chip.
Finite Element Simulation and Experiment of Chip Formation Process during Hig...IDES Editor
As an advanced manufacturing technology which
has been developed rapidly in recent years, high speed
machining is widely applied in many industries. The chip
formation during high speed machining is a complicated
material deformation and removing process. In research area
of high speed machining, the prediction of chip morphology is
a hot and difficult topic. A finite element method based on the
software ABAOUS which involves Johnson-Cook material
model and fracture criterion was used to simulate the serrated
chip morphology and cutting force during high speed
machining of AISI 1045 hardened steel. The serrated chip
morphology and cutting force were observed and measured by
high speed machining experiment of AISI 1045 hardened steel.
The effects of rake angle on cutting force, sawtooth degree
and space between sawteeth were discussed. The investigation
indicates that the simulation results are consistent with the
experiments and this finite element simulation method
presented can be used to predict the chip morphology and
cutting force accurately during high speed machining of
hardened steel.
Investigations on the surface roughness produced in turning of al6061 (as cas...eSAT Journals
Abstract: Surface roughness produced on the machined component is one of the key attribute of machining process. In this work the effect of various turning process parameters on surface roughness produced on Al6061 (as cast condition) is investigated. Also the effect of using coolant on surface roughness while turning is also determined. It is observed increase in cutting speed by 39.29% resulted in decrease of surface roughness by 31.44%. Increase in feed rate and depth of cut leads to increase in surface roughness. Quantitative analysis of surface roughness obtained in machining with coolant and without coolant is also presented. Keywords: Al6061, Surface Roughness, Turning Process, Spindle Speed, Depth of Cut, ANOVA
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.
Finite Element Simulation Analysis of Three-Dimensional Cutting Process Based...IJRES Journal
Metal cutting process is a complicated process of plastic deformation and the finite element
method is used to simulate the cutting process. Chip is an important product of the cutting process, it has
important significance to analysis of it's formation process and influence factors in the research of material
processing performance, cutting tool optimization, etc..In this paper, the three-dimensional orthogonal and
oblique cutting models were established based on Johnson-Cook material constitutive models and damage laws.
The formation process of chip was analyzed according to the metal simulation cutting process, the influence of
cutting variables (Cutting depth, Cutting speed, Work piece thickness)on chip was analyzed based on the status
of chip.
Finite Element Simulation of Serrated Chip Formation in High Speed CuttingIJRES Journal
The description of high speed cutting process with simulation based on finite element method provides huge superiorities compared to analytical and experimental models. This work focused on the study of high speed cutting process with finite element method, using commercial software ABAQUS/Explicit. The chip morphology is predicted, and the stress, strain and temperature in the chip are all simulated vividly when cutting stably. The serrated chip formation is explained by the adiabatic shear theory. The results showed that it is better to use the adiabatic shear theory to explain the formation of serrated chip.
Finite Element Simulation and Experiment of Chip Formation Process during Hig...IDES Editor
As an advanced manufacturing technology which
has been developed rapidly in recent years, high speed
machining is widely applied in many industries. The chip
formation during high speed machining is a complicated
material deformation and removing process. In research area
of high speed machining, the prediction of chip morphology is
a hot and difficult topic. A finite element method based on the
software ABAOUS which involves Johnson-Cook material
model and fracture criterion was used to simulate the serrated
chip morphology and cutting force during high speed
machining of AISI 1045 hardened steel. The serrated chip
morphology and cutting force were observed and measured by
high speed machining experiment of AISI 1045 hardened steel.
The effects of rake angle on cutting force, sawtooth degree
and space between sawteeth were discussed. The investigation
indicates that the simulation results are consistent with the
experiments and this finite element simulation method
presented can be used to predict the chip morphology and
cutting force accurately during high speed machining of
hardened steel.
Investigations on the surface roughness produced in turning of al6061 (as cas...eSAT Journals
Abstract: Surface roughness produced on the machined component is one of the key attribute of machining process. In this work the effect of various turning process parameters on surface roughness produced on Al6061 (as cast condition) is investigated. Also the effect of using coolant on surface roughness while turning is also determined. It is observed increase in cutting speed by 39.29% resulted in decrease of surface roughness by 31.44%. Increase in feed rate and depth of cut leads to increase in surface roughness. Quantitative analysis of surface roughness obtained in machining with coolant and without coolant is also presented. Keywords: Al6061, Surface Roughness, Turning Process, Spindle Speed, Depth of Cut, ANOVA
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.
Straight Bevel Gears Manufacturing Analysis by Conventional Powder Metallurgy...IOSRJMCE
In this paper it was proposed the manufacture of a component of the agricultural sector machine with conventional Powder Metallurgy (PM) techniques. The proposed process was developed with a Straight Bevel Gears, which is currently manufactured by other manufacturing processes, such as machining and forming. The gearwheel is part of a gearbox that replaces speed reduction. The component developed by powder metallurgy is low-carbon iron, in relation to Ni (nickel), Cu (copper) Mo (molybdenum) in large quantities. It was sought to verify the dimensional behavior with Statistical Process Control (SPC) techniques and also its properties through the analysis of the densities obtained in the gears during the powder metallurgy process. It was found that the parts fulfilled the requirements for coupling operation, such as those processed by other processing methods. The mechanical properties checked fully met the minimum requirements for these components. The chemical composition generated for the sprocket also pleased satisfied for this use.
Topology optimisation of hydraulic press structureeSAT Journals
Abstract Topology optimisation is carried out to find the zones of material removal on final size optimised structure. The results are represented and density plots are presented. The zones represented by blue can be removed for better material saving. The density plots are represented showing convergence of solution rapidly in the beginning and slowly in the later iterations. Finally wolf’s law is applied for material removal and addition for better strength. After iterations, the results are presented for vonmises and displacements. The results shows a vonmises stress of around 105 N/mm2 and a displacement value of 1.457mm. The final weight is observed to be around 15501kgs. The results shows efficiency of combination of three techniques in reducing the weigh of machine structures efficiently and useful for industrial applications as a combination. All the results are represented with necessary graphical pictures. The geometry is removed based on topology optimization and results are obtained based on wolff’s law. The structural results are presented. Keywords: Topoloyg1, optimisation2, vonmises stress3, Hydraulic press4 etc…
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.
Studies on material removal rate of al6061 while turning with coolant and wit...eSAT Journals
Abstract: Material Removal Rate (MRR) is one of the key attribute of machining process which influences productivity. In this work the effect of various turning process parameters on MRR produced on Al6061 (as cast condition) is investigated. Also, the effect of using coolant on MRR while turning is also determined. MRR is found to increase almost linearly with increase in feed rate. Increase in depth of cut and cutting speed is found to increase the MRR by 70.66 % and 16.36 % respectively. Keywords: Al6061, Material Removal Rate, Turning Process, Spindle Speed, Depth of Cut, ANOVA, Taguchi Method
Tichomir G. Vasilev, Wear of bronze bearing bushes after finishing with burni...Tihomir Vasilev
The article published results of experimental studies of wear of bronze bearings bushes, after finishing with burnishing.
Research addresses two types of bronze alloys widely used in practice for making bronze bearings operate under boundary or mixed film friction.
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 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.
Experimental Investigation and Analysis of Extrusion of Lead from Round Secti...IOSR Journals
Abstract : An experimental investigation has been done on the changes of die angle, area reduction in dies,
loading rate on the final extruded products, extrusion pressures of lead of circular cross sections of different
length. The proposed method is successfully adapted to the extrusion of the equilateral triangular section from
round billet through converging dies of different area reductions. Computation of extrusion pressure at various
area reductions and finite element analysis of different parameters (stress, strain, velocity) both in dry and wet
condition.
Keywords - Converging dies, Extrusion of the equilateral triangular section, Extrusion Pressure
“Gray Relational Based Analysis of Al-6351”iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Research Inventy : International Journal of Engineering and Scienceinventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Investigations on The Effects of Different Heat Transfer Coefficients in The ...IJRESJOURNAL
ABSTRACT: In the metal machining, the cutting fluid has become a tough problem in term of the health of works and environmental protection. The heat transfer coefficients of the water-based fluid, mineral oil and plant oil are distinct. An investigation focused on the effects of different heat transfer coefficients (h) on the cutting thickness compression ratio, chip formation, stress distribution and specific cutting energy is presented and discussed. In this study, three heat transfer coefficients have been simulated by Third WaveAdvantedge in machining AISI 1045 steel during different cutting speeds.It has been shown that the Mises stress and temperature are both affected by the heat transfer coefficient. When the h reaches higher, the Mises stress increases and the temperature shows the opposite trend. Also, the results can be found that the chip compression ratio decreases and shear angle increases when hrises. The relationship between specific cutting energy and heat transfer coefficients can be found in this paper.
Finite Element Modelling of Chip Formation in Orthogonal Machining for AISI 1050paperpublications3
Abstract: Finite element method has gained immense popularity in the area of metal cutting for providing detailed insight in to the chip formation process. This report presents an overview of the application of finite element method in the study of metal cutting process. The basics of both metal cutting and finite element methods, being the foremost in understanding the applicability of finite element method in metal cutting, have been discussed in brief. In this project, thermo mechanical simulation of turning process has been developed using commercially available finite element analysis software, ABAQUS 6.10. A 2-D orthogonal cutting has been modelled using an Arbitrary Lagrangian - Eulerian (ALE) formulation. The Johnson-Cook plasticity model has been assumed to describe the material behaviour during the process. Adaptive meshing dynamic explicit is also employed in this model to avoid the severe deformation. This study is aimed at temperature and stresses distributions during machining of AISI 1050 steel with three different speed 120m/min, feed 0.1 mm/rev. and depth of cut 1.5 mm. The results showed for speed 120 m/min, feed 0.1 and depth of cut 1.5 that the maximum stress for -7oC rake angle is 1.35 GPa while the maximum temperature results shown that 699°C.
ANN Model Based Calculation of Tensile of Friction Surfaced Tool Steelijtsrd
Friction surface treatment is well established solid technology and is used for deposition, abrasion and corrosion protection coatings on rigid materials. This novel process has wide range of industrial applications, particularly in the field of reclamation and repair of damaged and worn engineering components. In this paper, present the prediction of tensile of friction surface treated tool steel using ANN for simulated results of friction surface treatment. This experiment was carried out to obtain tool steel coatings of low carbon steel parts by changing input process parameters such as friction pressure, rotational speed and welding speed. The simulation is performed by a 33 factor design that takes into account the maximum and minimum limits of the experimental work performed by the 23 factor design. Neural network structures, such as the Feed Forward Neural Network FFNN , were used to predict tensile tool steel sediments caused by friction. V. Pitchi Raju "ANN Model Based Calculation of Tensile of Friction Surfaced Tool Steel" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-6 , October 2019, URL: https://www.ijtsrd.com/papers/ijtsrd29169.pdf Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/29169/ann-model-based-calculation-of-tensile-of-friction-surfaced-tool-steel/v-pitchi-raju
Straight Bevel Gears Manufacturing Analysis by Conventional Powder Metallurgy...IOSRJMCE
In this paper it was proposed the manufacture of a component of the agricultural sector machine with conventional Powder Metallurgy (PM) techniques. The proposed process was developed with a Straight Bevel Gears, which is currently manufactured by other manufacturing processes, such as machining and forming. The gearwheel is part of a gearbox that replaces speed reduction. The component developed by powder metallurgy is low-carbon iron, in relation to Ni (nickel), Cu (copper) Mo (molybdenum) in large quantities. It was sought to verify the dimensional behavior with Statistical Process Control (SPC) techniques and also its properties through the analysis of the densities obtained in the gears during the powder metallurgy process. It was found that the parts fulfilled the requirements for coupling operation, such as those processed by other processing methods. The mechanical properties checked fully met the minimum requirements for these components. The chemical composition generated for the sprocket also pleased satisfied for this use.
Topology optimisation of hydraulic press structureeSAT Journals
Abstract Topology optimisation is carried out to find the zones of material removal on final size optimised structure. The results are represented and density plots are presented. The zones represented by blue can be removed for better material saving. The density plots are represented showing convergence of solution rapidly in the beginning and slowly in the later iterations. Finally wolf’s law is applied for material removal and addition for better strength. After iterations, the results are presented for vonmises and displacements. The results shows a vonmises stress of around 105 N/mm2 and a displacement value of 1.457mm. The final weight is observed to be around 15501kgs. The results shows efficiency of combination of three techniques in reducing the weigh of machine structures efficiently and useful for industrial applications as a combination. All the results are represented with necessary graphical pictures. The geometry is removed based on topology optimization and results are obtained based on wolff’s law. The structural results are presented. Keywords: Topoloyg1, optimisation2, vonmises stress3, Hydraulic press4 etc…
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.
Studies on material removal rate of al6061 while turning with coolant and wit...eSAT Journals
Abstract: Material Removal Rate (MRR) is one of the key attribute of machining process which influences productivity. In this work the effect of various turning process parameters on MRR produced on Al6061 (as cast condition) is investigated. Also, the effect of using coolant on MRR while turning is also determined. MRR is found to increase almost linearly with increase in feed rate. Increase in depth of cut and cutting speed is found to increase the MRR by 70.66 % and 16.36 % respectively. Keywords: Al6061, Material Removal Rate, Turning Process, Spindle Speed, Depth of Cut, ANOVA, Taguchi Method
Tichomir G. Vasilev, Wear of bronze bearing bushes after finishing with burni...Tihomir Vasilev
The article published results of experimental studies of wear of bronze bearings bushes, after finishing with burnishing.
Research addresses two types of bronze alloys widely used in practice for making bronze bearings operate under boundary or mixed film friction.
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 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.
Experimental Investigation and Analysis of Extrusion of Lead from Round Secti...IOSR Journals
Abstract : An experimental investigation has been done on the changes of die angle, area reduction in dies,
loading rate on the final extruded products, extrusion pressures of lead of circular cross sections of different
length. The proposed method is successfully adapted to the extrusion of the equilateral triangular section from
round billet through converging dies of different area reductions. Computation of extrusion pressure at various
area reductions and finite element analysis of different parameters (stress, strain, velocity) both in dry and wet
condition.
Keywords - Converging dies, Extrusion of the equilateral triangular section, Extrusion Pressure
“Gray Relational Based Analysis of Al-6351”iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Research Inventy : International Journal of Engineering and Scienceinventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Investigations on The Effects of Different Heat Transfer Coefficients in The ...IJRESJOURNAL
ABSTRACT: In the metal machining, the cutting fluid has become a tough problem in term of the health of works and environmental protection. The heat transfer coefficients of the water-based fluid, mineral oil and plant oil are distinct. An investigation focused on the effects of different heat transfer coefficients (h) on the cutting thickness compression ratio, chip formation, stress distribution and specific cutting energy is presented and discussed. In this study, three heat transfer coefficients have been simulated by Third WaveAdvantedge in machining AISI 1045 steel during different cutting speeds.It has been shown that the Mises stress and temperature are both affected by the heat transfer coefficient. When the h reaches higher, the Mises stress increases and the temperature shows the opposite trend. Also, the results can be found that the chip compression ratio decreases and shear angle increases when hrises. The relationship between specific cutting energy and heat transfer coefficients can be found in this paper.
Finite Element Modelling of Chip Formation in Orthogonal Machining for AISI 1050paperpublications3
Abstract: Finite element method has gained immense popularity in the area of metal cutting for providing detailed insight in to the chip formation process. This report presents an overview of the application of finite element method in the study of metal cutting process. The basics of both metal cutting and finite element methods, being the foremost in understanding the applicability of finite element method in metal cutting, have been discussed in brief. In this project, thermo mechanical simulation of turning process has been developed using commercially available finite element analysis software, ABAQUS 6.10. A 2-D orthogonal cutting has been modelled using an Arbitrary Lagrangian - Eulerian (ALE) formulation. The Johnson-Cook plasticity model has been assumed to describe the material behaviour during the process. Adaptive meshing dynamic explicit is also employed in this model to avoid the severe deformation. This study is aimed at temperature and stresses distributions during machining of AISI 1050 steel with three different speed 120m/min, feed 0.1 mm/rev. and depth of cut 1.5 mm. The results showed for speed 120 m/min, feed 0.1 and depth of cut 1.5 that the maximum stress for -7oC rake angle is 1.35 GPa while the maximum temperature results shown that 699°C.
ANN Model Based Calculation of Tensile of Friction Surfaced Tool Steelijtsrd
Friction surface treatment is well established solid technology and is used for deposition, abrasion and corrosion protection coatings on rigid materials. This novel process has wide range of industrial applications, particularly in the field of reclamation and repair of damaged and worn engineering components. In this paper, present the prediction of tensile of friction surface treated tool steel using ANN for simulated results of friction surface treatment. This experiment was carried out to obtain tool steel coatings of low carbon steel parts by changing input process parameters such as friction pressure, rotational speed and welding speed. The simulation is performed by a 33 factor design that takes into account the maximum and minimum limits of the experimental work performed by the 23 factor design. Neural network structures, such as the Feed Forward Neural Network FFNN , were used to predict tensile tool steel sediments caused by friction. V. Pitchi Raju "ANN Model Based Calculation of Tensile of Friction Surfaced Tool Steel" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-6 , October 2019, URL: https://www.ijtsrd.com/papers/ijtsrd29169.pdf Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/29169/ann-model-based-calculation-of-tensile-of-friction-surfaced-tool-steel/v-pitchi-raju
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.
EXPERIMENTAL ANALYSIS AND MODELLING OF GRINDING AISI D3 STEELijmech
Grinding of hardened steels for the realisation of better surface quality of the workpiece is an essentiality
of high productivity environments. The surface grinding of high carbon high chromium steels like AISI D3
with a production level grinding wheel used in the industry is the driver of the present research article. The
experimentation is done in dry as well as pool cooling conditions to ascertain the better of the two
conditions in providing a better set of cutting forces and surface finish. A mathematical model for
evaluating the forces generated during grinding is evolved and on comparison of the results obtained from
the model with the ones from experimentation is found to be correlating. The usage of production level
vitrified grinding wheel has shown good results in terms of lower forces generated and good surface finish
during surface grinding. The results are optimised and the set of inputs which yield good surface finish and
low forces are given. Dry grinding of AISI D13 yields good surface finish than wet grinding. Surface finish
of 0.14 microns is achievable using dry grinding.
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
Optimization of the Superfinishing Process Using Different Types of StonesIDES Editor
Super finishing is a micro-finishing process that
produces a controlled surface condition on circular parts. It is
not primarily a sizing operation and its major purpose is to
produce a surface on a work piece capable of sustaining uneven
distribution of a load by improving the geometrical accuracy.
The wear life of the parts micro finished to maximum
smoothness is extended considerably. Super finishing is a
slow speed, low temperature, high precision abrasive
machining operation for removing minute amounts of surface
material In this paper critical parameters which affects surface
roughness are determined. According to the design of
experimentation, mathematical model for four different types
of abrasive stones used is proposed. In order to get minimum
values of the surface roughness, optimization of the
mathematical model is done and optimal values of the
examined factors are determined. The obtained results are,
according to the experiment plan, valid for the testing of
material MS12.
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.
Modeling of Rough Surface and Contact Simulationijsrd.com
As a result of limitation of manufacturing processes, real surfaces always have some roughness and surface curvature. In many heat transfer applications, the perfectly smooth surfaces are necessary to transmit the heat. Due to the surface curvature of contacting bodies, the macro-contact area is formed, the area where micro-contacts are distributed randomly. The real contact occurs only over microscopic contacts. The heat flow must pass through the macro-contact and then micro-contacts to transfer from one body to another to form heat conductance. This phenomenon leads to a relatively high temperature drop across the interface. Thermal contact resistance (TCR) is a complex interdisciplinary problem, which includes geometrical, mechanical, and thermal analyses. In this paper, geometric modeling of asperities of rough surface 2 μm, 3.2 μm and 15μm surface roughness's is done in ANSYS and the number of asperities and areal contact area is found. The simulation is done with 1.8MPa pressure and with SS 304 as material for all above mentioned surface roughness's. The contacting bodies are kept at LN2 temperature and atmospheric temperature.
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.
Modeling and Analysis for Cutting Temperature in Turning of Aluminium 6063 Us...IOSR Journals
Deviation in machining process due to the temperature influence, cutting force, tool wear leads to
highly inferior quality of finished product, especially in high speed machining operations where product quality
and physical dimensions seems to be meticulous. Moreover, temperature is a significant noise parameter which
directly affects the cutting tool and work piece. Hence the aim of this project work is to study the machining
effect on 6063 Aluminium alloy at varies combinations of process parameters such as speed, feed rate and depth
of cut; and also to determine the effect of those parameters over the quality of finished product. A L27
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Thinning and springback prediction of Mg alloy AZ31 in deep drawing process – Influence of BHF and friction conditions
1. International Journal of Civil, Mechanical and Energy Science,6(6)
Nov-Dec, 2020 | Available:http://ijcmes.com/
ISSN: 2455-5304
https://dx.doi.org/10.22161/ijcmes.66.1 14
Thinning and springback prediction of Mg alloy
AZ31 in deep drawing process – Influence of
BHF and friction conditions
Marina Maia Araripe1
, Francisco Elicivaldo Lima2
, Rômulo do Nascimento
Rodrigues3
1,2
Manufacturing, Quality and Sustainability Center (NMQS), Department of Mechanical engineering, Federal University of Ceará, Brazil
3
Mechanical Vibration Laboratory (LVM), Department of Mechanical engineering, Federal University of Ceará, Brazil
Abstract— Magnesium is nowadays the lighter metal used in structural applications with expressive
advantages over steel and aluminum. Due to its low density and high specific strength, magnesium alloys
represent a promising alternative, especially for applications in automobile industry, being used in structural
components in order to reduce weight and, consequently, improve fuel efficiency. In the recent decades,
several researches have been performed in order to improve the use of Mg alloys in forming process since
its formability is strongly affected by some conditions as temperature. In this study, a Finite Element Analysis
(FEA) is performed to simulate the sheet metal deep drawing process of the magnesium alloy AZ31. The
main objective is to evaluate the effect of the blank holder force and friction conditions in the formability by
predicting results of springback, thickness distribution and thinning of the sheet metal blank. In total, 54
simulations were performed.
Keywords— Blank holder force, Deep drawing, Finite elements, Friction, Lightweight alloy, Metal
forming, Springback, Thickness distribution.
I. INTRODUCTION
In the past decades, the use of lightweight structures for
several industrial fields, specially vehicles manufacturers,
have been progressively encouraged due to decrease offuel
consumption and decline in 𝐶𝑂2emissions into the
atmosphere [1]. Among the lightweight metals, magnesium
and its alloys has gained much attention due to its density
and high strength-to-weight ratio among other structural
metals [2]. Besides, magnesium alloys have superior
qualities like recycling facility, better manufacturability and
good dimensional stability.
Generally, the traditional methods to test metal forming
properties are experimentally, applying trial-and-error and
empirical-techniques, which are costly and time-
consuming, since the whole tooling part, such dies, blank
holders and punches needs to be designed and
manufactured. By using a finite element model and
simulating it, it is possible to predict several results and save
resources, as time and money. Numerical simulation not
only acts as a design verification tool, but also becomes an
important method to explore the optimization of process
parameters [3,4,5].
There are many significant forming parameters that are
influencing on deep drawing process, such as punch nose
radius, die shoulder radius, blank holder force, coefficients
of friction, forming temperature, punch speed, clearance
between punch and die and others. Among there, blank
holder force and coefficients of friction play a vital role in
the final quality of the workpiece, being fundamental
parameters in order to prevent the appearance of ears,
wrinkles and even the failure.
The main objective of this work is to simulate the deep
drawing process of magnesium alloy AZ31 and evaluate the
effect of blank holder force and friction coefficients in final
thickness distribution, thinning of the blank and springback.
54 non-linear simulations were performed: 27 dynamic
(deep drawing) and 27 static (springback). The first type
lasted 0,028s and the second one, 0,1s.
2. International Journal of Civil, Mechanical and Energy Science,6(6)
Nov-Dec, 2020 | Available:http://ijcmes.com/
ISSN: 2455-5304
https://dx.doi.org/10.22161/ijcmes.66.1 15
II. SIMULATION OF DEEP DRAWING PROCESS
2.1 Finite element model
Fig. 1 shows the model of the tooling. The blank is a circular
sheet that will be positioned between the blank holder and
the die. Dimensions regarding the die, punch, blank holder
and blank are given in Table 1. Due to the symmetry, the
numerical analysis of the deep drawing process was
performed by using just one quarter of the model in order to
fit in the nodes limit permitted by Abaqus Student Version.
Fig. 1: Model of the drawing tooling
Table 1: Parameters’ geometrical dimensions
2.2 Material properties
The blank is made of Mg alloy AZ31. In order to represent
the material some properties of the alloy were informed to
the software, those are given in Table 2 [7]. Besides, to
describe the plastic behavior, the True Stress x True Strain
curve were calculated following the parameters in Table 3.
Table 2: Properties of AZ31 alloy
Density 1.77 x 10−9
Young’s Modulus 45000 MPa
Poisson’s ratio 0.35
Table 3: Flow stress calculation parameters
Strain hardening exponent n = 0.18565966
Hardening coefficient K= 302.913767
Temperature T(K) = 523
Strain rate e (s-¹) 0.1
Strain rate sensitivity exponent m = 0.09925048
In Table 3, only 2 parameters were chosen: temperature and
strain rate. The others were also calculated by using the
equations (1-3) [8]:
𝑛 = 0.031 + 0.013 log 𝜀̇ +
97.1
𝑇
(1)
𝑚 =
−145.263
+ 0.377 (2)
𝑇
𝐾 = −156.4 + 9.1 log 𝜀̇ +
244980.4
𝑇
(3)
Regarding the meshing, the blank sheet was the only part
considered deformable with a planar shell base and it was
meshed with S4R shell type element [6], the element size
was 2.5. The tooling was modeled by using analytical rigid
form. Neither the punch, die and blank holder were meshed.
The parameters’ result calculation is as shown in Table 3.
Then were used equations (4,5) to estimate the true stress x
true strain curve shown in Fig. 2, which was validated by
being compared with others flow stress curves obtained
experimentally under the same conditions (temperature and
strain rate) [8, 9].
𝜎 = 𝐾𝜀̇ 𝑛 𝜀̇ 𝑚 (4)
𝜎 = 18015 𝜀̇0.16𝜀̇0.083exp (−0.0078𝑇 − 0.8903𝜀̇) (5)
(4) is valid to deformation values (𝜀̇) between 0.02 and 0.3,
temperature values (T) between 423 and 573K and strain
rate values (𝜀̇) between 0.1 and 0.0001s-¹. While (5) is valid
to deformation values (𝜀̇) between 0.15 and 0.45,
temperature values (T) between 473 and 573K and strain
rate values (𝜀̇) between 0.1 and 0.0001s-¹.
Blank holder
Height 1.2 mm
Profile radius 2mm
Min. radius 39.83 mm
Max. Radius 70.18mm
Die
Height 15.5 mm
Shoulder
radius
5 mm
Min. radius 29.83 mm
Max. Radius 62.8 mm
Sheet
Radius 50 mm
Thickness 1.2 mm
Punch
Depth 49mm
Nose radius 5 mm
Radius 25 mm
3. International Journal of Civil, Mechanical and Energy Science,6(6)
Nov-Dec, 2020 | Available:http://ijcmes.com/
ISSN: 2455-5304
https://dx.doi.org/10.22161/ijcmes.66.1 16
250
200
150
100
50
0
0.0 0.1 0.2 0.3 0.4
True strain
In the present work, a range regarding the blank holder force
was considered varying from 0.1 kN to 35 kN.
2.3.2 Lubrication conditions
The friction in deep drawing plays a vital role in deep
drawing affecting the stress and strains in the blank during
the forming work. Besides, it is one of the major factors that
determine the required punch force and blank holder force.
Therefore, lubrication conditions affect the energy needed
to deform the sheet. Concluding, the optimization of the
Fig. 2: True stress x true strain of AZ31 alloy (T = 523K
and 𝜀̇ = 0.1s-¹)
Furthermore, in order to describe the anisotropic behavior
of the Mg alloy, Lankford coefficients obtained
experimentally by Reddy [9] were used to evaluate
anisotropic parameters according to Hill’s criteria (6-8).
𝑟0 = 1.30
𝑟45 = 2.50
𝑟90 = 1.05
By assuming 𝑅11 = 𝑅13 = 𝑅23 = 1:
friction coefficients is an important task in order to obtain
an acceptable workpiece shape and to improve the energy
efficiency. In the present work, two friction coefficients
were considered:
- Friction coefficient between upper surface and punch and
blank holder ( 𝜇 𝑢): varying from 0.05 to 1.0
- Friction coefficient between lower surface and die ( 𝑙):
varying from 0.05 to 0.5.
2.4 Output extraction
2.4.1 Thickness distribution
The study of thickness distribution is important to rate the
uniformity of the blank walls and the behavior of each
R22 =
𝑅 =
r90(r0+1)
√
r0(r90+1)
𝑟90(𝑟0+1)
(7)
(6) region of the workpiece. This factor was evaluated by
creating a path of 8 nodes along the blank, from the center
to the extremity of the blank and extracting the section
33
𝑅12
√
(𝑟0+𝑟90)
= √
3(𝑟0+1)𝑟90
(2𝑟45+1)(𝑟0+𝑟90) (8)
thickness value of each node.
Then resulting as shown in Table 4:
Table 4: Anisotropy parameters of AZ31
Anisotropy parameters AZ31 alloy
𝑅11 𝑅22 𝑅33 𝑅12 𝑅13 𝑅23
1 0.9519 1.013735 0.716819 1 1
2.3 Drawing operation parameters
2.3.1 Blank holder force (BHF)
The force applied by the blank holder aim to prevent
wrinkling and depends on limit drawing ratio (LDR),
blank’s thickness and blank’s material. The BHF required
in deep drawing process varies from very little to a
maximum of one third of the drawing pressure [10]. The
higher the BHF, the greater will be the strain over the punch
face, although the drawing process is limited by the strain
in the side-wall.
Fig. 3: STH node path along the blank after deep drawing
process
Fig. 3 illustrates the thickness variation in each region.
Since the initial blank thickness was 1.2 mm, by looking to
the scale, is possible to notice that the thickness walls varied
from 1.025 to 1.268 mm approximately after deep drawing.
Nevertheless, in the present study, the results were not just
evaluated by analyzing the scale colors. A report with the
exactly STH values of each node was extracted from each
simulation.
Truestress(MPa)
R22 = √
r90(r0+1)
r0(r90+1)
(6)
𝑅33 = √
𝑟90(𝑟0+1)
(𝑟0+𝑟90)
(7)
𝑅12 = √
3(𝑟0+1)𝑟90
(2𝑟45+1)(𝑟0+𝑟90)
(8)
4. International Journal of Civil, Mechanical and Energy Science,6(6)
Nov-Dec, 2020 | Available:http://ijcmes.com/
ISSN: 2455-5304
https://dx.doi.org/10.22161/ijcmes.66.1 17
2.4.2 Thinning
In order to evaluate the thinning of each region, the equation
(9) was utilized.
(conclusion of the springback) was calculated and the
simple average was performed, obtaining the percentage
of springback under the referred conditions.
𝑆𝑇𝐻𝐼𝑁 = 1 −
𝑆𝑇𝐻
𝑆𝑇𝐻 𝑜𝑟𝑖𝑔
In which,
STHIN = thickness thinning (%);
STH = evaluated thickness (mm);
𝑆𝑇𝐻 𝑜𝑟𝑖𝑔 = original thickness (mm).
(9)
III. RESULTS AND DISCUSSION
3.1 Blank holder effect
3.1.1 In thickness distribution
The thinning was evaluated for each node according to the
previous item and the average thinning of the nodes was
calculated for each simulated condition.
2.4.3 Springback
Alike to thickness distribution evaluation method, a set of
nodes was established, but another path was adopted, as
illustrated in Fig. 4. In addition, all possible nodes were
selected, totaling 22.
To evaluate the springback it was necessary to perform a
static explicit non-linear simulation, in which the beginning
was characterized by the final results of the previous
simulation (deep drawing) and the difference between the
two was both in type (this one being static and the previous
one, dynamic), as in privation of contact with the other
components of the process (blank holder, die and punch).
Fig. 4: Springback node path along the blank after deep
drawing process
The results used were those of magnitude, also obtained
in a report format. The difference between magnitudes
obtained at the beginning of the static simulation (end of
the dynamic) and at the end of the static simulation
Analyzing the Table 5, it appears that the average that
keep closest to the original thickness of the blank (1.2
mm) is the one obtained with the application of 25 kN
load. However, it was observed that with the load of
30 kN the standard deviation was the smallest
calculated, being therefore the load that provides less
disparity in thickness along the blank. From a different
perspective, it appears that the value of 0.1 kN
presented both the farthest average from the original
thickness and the largest standard deviation.
From Fig. 5, it is clear that for all applied blank holder
forces, the most discrepant point from the others is ‘3’,
which corresponds to a region close to the bottom fold
of the cup. As expected, the regions closest to the
center of the glass, at the bottom, ‘1’ and ‘2’ suffered a
slight accumulation of material, while the ‘5 to 8’ wall
regions suffer a loss due to stretching. The obtained
curve is similar to the results of another study [11]
regarding the influence of the force of the blank holder
on the distribution of final thickness.
Fig. 5: BHF effect in thickness distribution
𝑆𝑇𝐻𝐼𝑁 = 1 −
𝑆𝑇𝐻
𝑆𝑇𝐻 𝑜𝑟𝑖𝑔
(9)
5. International Journal of Civil, Mechanical and Energy Science,6(6)
Nov-Dec, 2020 | Available:http://ijcmes.com/
ISSN: 2455-5304
https://dx.doi.org/10.22161/ijcmes.66.1 18
Table 5: BHF effect in thickness distribution
Measured Locations (mm)
BHF (kN)
0.1 2.5 5 10 15 20 25 30 35
1 1.236 1.244 1.235 1.235 1.235 1.235 1.235 1.236 1.235
2 1.219 1.220 1.217 1.217 1.217 1.217 1.217 1.218 1.217
3 1.115 1.117 1.114 1.113 1.112 1.111 1.112 1.114 1.112
4 1.148 1.146 1.149 1.150 1.151 1.151 1.152 1.152 1.150
5 1.146 1.150 1.152 1.155 1.157 1.158 1.160 1.159 1.157
6 1.157 1.180 1.180 1.182 1.184 1.184 1.184 1.182 1.179
7 1.151 1.177 1.178 1.179 1.181 1.183 1.185 1.181 1.177
8 1.130 1.179 1.180 1.182 1.185 1.188 1.188 1.180 1.178
Average 1.162 1.177 1.176 1.177 1.178 1.178 1.179 1.178 1.176
Standard deviation 0.042 0.041 0.038 0.039 0.039 0.039 0.038 0.038 0.038
3.1.2 In thinning
Table 6: BHF effect in thinning (%)
Measured Locations (mm)
BHF (kN)
0.1 2.5 5 10 15 20 25 30 35
1 0.030 0.037 0.030 0.030 0.029 0.029 0.029 0.030 0.029
2 0.016 0.017 0.014 0.014 0.014 0.014 0.014 0.015 0.014
3 0.071 0.069 0.072 0.073 0.074 0.074 0.073 0.072 0.073
4 0.044 0.045 0.042 0.041 0.041 0.041 0.040 0.040 0.041
5 0.045 0.041 0.040 0.037 0.036 0.035 0.033 0.034 0.036
6 0.036 0.017 0.017 0.015 0.013 0.013 0.014 0.015 0.017
7 0.041 0.019 0.018 0.017 0.016 0.014 0.012 0.016 0.019
8 0.058 0.017 0.017 0.015 0.013 0.010 0.010 0.017 0.019
Average 0.043 0.033 0.031 0.030 0.029 0.029 0.028 0.030 0.031
% 4.26 3.27 3.12 3.04 2.94 2.89 2.82 2.99 3.11
From the Table 6. it is possible to notice the significant
thinning in the ‘3’ region. as previously observed in
the analysis of the thickness distribution.
From Fig. 6 it can be noticed that the greatest thinning
occurs with the application of the smallest BFH (0.1
kN) and that there is a downward trend to the
minimum (25 kN), from which the thinning grows
again. This behavior can be explained by the fact that
higher BHF values result in increased tensions in the
glass walls [11].
Fig. 6: BHF effect in thinning
6. International Journal of Civil, Mechanical and Energy Science,6(6)
Nov-Dec, 2020 | Available:http://ijcmes.com/
ISSN: 2455-5304
https://dx.doi.org/10.22161/ijcmes.66.1 19
3.1.3 In springback
The blank holder force is one of the parameters of vital
influence on the springback. It is a consensus among
countless authors that the optimized application of BHF is
the solution for high springback values and other problems
of deep drawing.
From the Table 7 and the Fig. 7, it is possible to perceive a
point of minimum spring back when the BHF applied is 5
kN and a subtle growth trend as the blank holder force
increases. This same behavior, in which the springback
increases subtly as the BHF increases, was found by other
research in which numerous experimental tests were
carried out in order to study the influence of BHF on the
springback [12].
Table 7: BHF effect in springback (%)
BHF (kN)
0.1 2.5 5 10 15 20 25 30 35
0.43 0.46 0.35 0.35 0.36 0.36 0.37 0.37 0.38
From the Table 7 and the Fig. 7, it is possible to perceive a
point of minimum spring back when the BHF applied is 5
kN and a subtle growth trend as the blank holder force
increases. This same behavior, in which the springback
increases subtly as the BHF increases, was found by other
research in which numerous experimental tests were
carried out in order to study the influence of BHF on the
springback [12].
Fig. 7: BHF effect in springback
3.2 Friction coefficient between upper surface, blank
holder and punch effect
As previously discussed, friction has a significant effect on
the metal conformation. Two factors influence the friction
coefficient value: the nature of the surfaces in contact and
the nature of the lubricant used. For the present work,
friction coefficient ranges were considered according to
Mang and Dresel [13].
3.2.1 In thickness distribution
Table 8: Upper friction coefficient effect in thickness distribution
Fluid lubricant Solid lubricant Dry lubricant
Measured
Locations (mm)
𝜇 𝑢
0.05 0.1 0.15 0.3 0.5 0.55 0.6 0.65 07 1
1 1.242 1.239 1.235 1.224 1.218 1.217 1.217 1.216 1.215 1.209
2 1.230 1.223 1.216 1.199 1.197 1.197 1.197 1.197 1.197 1.194
3 1.146 1.129 1.111 1.049 1.086 1.113 1.127 1.136 1.144 1.159
4 1.162 1.157 1.151 1.131 1.086 0.980 0.788 0.855 0.829 0.691
5 1.153 1.155 1.157 1.160 1.164 1.164 1.164 1.162 1.161 1.115
6 1.178 1.181 1.184 1.190 1.193 1.194 1.194 1.195 1.195 1.193
7 1.175 1.178 1.181 1.188 1.192 1.192 1.193 1.193 1.193 1.193
8 1.179 1.182 1.185 1.190 1.193 1.193 1.194 1.194 1.194 1.194
Average 1.183 1.180 1.178 1.166 1.166 1.156 1.134 1.143 1.141 1.119
Failure occurred
7. International Journal of Civil, Mechanical and Energy Science,6(6)
Nov-Dec, 2020 | Available:http://ijcmes.com/
ISSN: 2455-5304
https://dx.doi.org/10.22161/ijcmes.66.1 20
From the simulations’ results shown in Table 8 and Fig. 8,
the occurrence of failure was found when coefficients of
friction applied to the upper surface of the blank are equal
to or greater than μ = 0.55, this happens due to the increase
in stresses, and consequently deformations. It is also
observed that the point where there is a failure is ‘4’, an
equivalent region to the bottom edge of the cup.
Fig. 8: Upper friction coefficient effect in thickness
distribution
At Fig. 8, there is a significant difference in thickness in
the ‘4’ region, starting from μ = 0.60. In addition, it is
observed that for μ-values up to 0.15, the thickness
distribution is considerably uniform.
3.2.2 In thinning
The results obtained for the thinning shown in Table 9 and
Fig. 9 point at two mean peaks, one at μ = 0.6 and the
other at μ = 1, this one being considered the value that
provides lower uniformity pieces. On the other hand, good
uniformity is observed as the friction coefficient decreases,
although μ values between 0.05 and 0.5 show very close
values. Despite this apparent better uniformity that the
lower friction value presents, it is important to consider the
formation of wrinkles and ears, which is quite recurrent in
friction values that are too low on the upper surface of the
blank, especially in the flange region, regarding contact
with the blank holder.
Fig. 9: Upper friction coefficient effect in thinning
Table 9: Upper friction coefficient effect in thinning
Fluid lubricant Solid lubricant Dry lubricant
Measured
Locations
(mm)
𝜇 𝑢
0.05 0.1 0.15 0.3 0.5 0.55 0.6 0.65 0.7 1
1 0.035 0.032 0.029 0.020 0.015 0.014 0.014 0.013 0.012 0.008
2 0.025 0.019 0.014 0.001 0.002 0.002 0.002 0.002 0.003 0.005
3 0.045 0.059 0.074 0.126 0.095 0.073 0.061 0.054 0.046 0.034
4 0.031 0.036 0.041 0.057 0.095 0.183 0.343 0.288 0.309 0.424
5 0.039 0.037 0.036 0.033 0.030 0.030 0.030 0.032 0.032 0.071
6 0.018 0.016 0.013 0.009 0.006 0.005 0.005 0.005 0.004 0.006
7 0.021 0.018 0.016 0.010 0.007 0.007 0.006 0.006 0.005 0.006
8 0.018 0.015 0.013 0.008 0.006 0.006 0.005 0.005 0.005 0.005
Average 0.029 0.029 0.029 0.033 0.032 0.040 0.058 0.051 0.052 0.070
% 2.90 2.91 2.94 3.30 3.20 3.99 5.83 5.05 5.22 6.96
8. International Journal of Civil, Mechanical and Energy Science,6(6)
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3.2.3 In springback
Table 10: Upper friction coefficient effect in springback
(%)
Fluid lubricant
Solid
lubricant
Dry lubricant
𝜇 𝑢
0.05 0.1 0.15 0.3 0.5 0.5 - 1
0.40 0.38 0.36 0.27 0.22
Failure
occurred
Not considering the criteria of wrinkling and ear formation,
from the results previously shown, it would certainly be
concluded that the adequate values for friction of the upper
surface would follow the rule of “the smaller, the better”.
On the other hand, the results obtained for the springback
lead to a reconsideration. As explained in the previous item,
the thinning averages obtained for μ from 0.05 to 0.5 were
very close. As shown in Table 10 and Fig. 10, the
springback values are significantly different. For μ = 0.5, a
springback of 0.22% was obtained, practically half of the
value obtained for μ = 0.05 (0.40%).
Possibly, the ideal value for the upper friction would be
between μ = 0.15 and μ = 0.30, to obtain reasonable values
for both the elastic return and the uniformity of the part.
Fig. 10: Upper friction coefficient effect in springback
3.3 Friction coefficient between lower surface and die
effect
It is usually preferable the coefficient of friction between
the die and the blank to be as low as possible. Even excess
lubrication does not raise major concerns on these surfaces,
except for cases with complex die shapes or large areas,
such as car door stamping, in which excess lubricant can
cause deviations during work.
3.3.1 In thickness distribution
Considering the values shown in Table 11, it appears that
from μ = 0.3 there is a failure. There is also a trend of
displacement of the failure region, which starts in the region
'3' to μ = 0.2 and μ = 0.25, moves to '4' when μ = 0.3 and
ends in '5 ', in a region corresponding to the side walls of the
cup, for μ = 0.4 and μ = 0.5. This trend is even clearly
noticed by analyzing Fig. 11.
Table 11: Lower friction coefficient effect in thickness distribution
Fluid lubricant Solid lubricant
Measured
Locations (mm)
𝜇𝑙
0.05 0.1 0.15 0.2 0.25 0.3 0.4 0.5
1 1.245 1.240 1.235 1.230 1.224 1.223 1.217 1.212
2 1.228 1.222 1.216 1.211 1.209 1.210 1.208 1.205
3 1.155 1.134 1.111 1.090 1.092 1.153 1.186 1.190
4 1.171 1.163 1.151 1.136 1.118 1.044 1.129 1.127
5 1.162 1.160 1.157 1.152 1.140 1.106 1.054 1.014
6 1.190 1.188 1.184 1.178 1.165 1.148 1.134 1.128
7 1.188 1.186 1.181 1.174 1.161 1.143 1.130 1.125
8 1.190 1.188 1.185 1.179 1.167 1.151 1.139 1.134
Average 1.191 1.185 1.178 1.169 1.159 1.147 1.150 1.142
Failure occurred
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3.3.2 In thinning
From the results obtained for the effect of the friction
coefficient of the die with the blank, shown in Table 12 and
Fig. 12, it is possible to notice, as before, two peaks in the
thinning averages, one at μ = 0.3 and the other at μ = 0.5,
both with results very close, characterized as the
coefficients that result in a worse uniformity of the piece.
From another perspective, good uniformity is observed as
the friction coefficient decreases, with the μ value range
between 0.05 and 0.15 being the most beneficial in relation
to the thickness homogeneity.
Table 12: Lower friction coefficient effect in thinning
Fluid lubricant Solid lubricant
Measured
Locations (mm)
𝜇𝑙
0.05 0.1 0.15 0.2 0.25 0.3 0.4 0.5
1 0.037 0.033 0.029 0.025 0.020 0.019 0.014 0.010
2 0.024 0.018 0.014 0.010 0.007 0.009 0.007 0.004
3 0.038 0.055 0.074 0.092 0.090 0.039 0.012 0.009
4 0.024 0.031 0.041 0.053 0.069 0.130 0.059 0.061
5 0.032 0.034 0.036 0.040 0.050 0.078 0.122 0.155
6 0.008 0.010 0.013 0.019 0.029 0.044 0.055 0.060
7 0.010 0.012 0.016 0.021 0.033 0.047 0.058 0.062
8 0.008 0.010 0.013 0.018 0.028 0.041 0.051 0.055
Average 0.022 0.025 0.029 0.035 0.041 0.051 0.047 0.052
% 2.24 2.54 2.95 3.47 4.08 5.09 4.72 5.19
3.3.3 In springback
Table 13: Lower friction coefficient effect in springback (%)
Fluid lubricant Solid lubricant
0.05 0.1 0.15 0.2 0.25 0.3 - 0.5
0.388 0.373 0.358 0.347 0.336
Failure
occurred
Fig.12: Lower friction coefficient effect in
thinning
Table 13 and Fig. 13 shows the results obtained for the
springback and they proved to be quite similar for the
range of μ = 0.5 to μ = 0.25, so this would not be a critical
criterion for choosing the coefficient. Summing up, μ
values between 0.1 and 0.15 would be preferable due to
their good results for blank uniformity and springback.
Fig. 11: Lower friction coefficient effect in thickness
distribution
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Fig. 13: Lower friction coefficient effect in springback
IV. CONCLUSIONS
The results obtained in the simulations brought important
reflections related to the effect of friction and blank holder
force on springback behavior, thickness distribution and
thinning, consenting with the studied literary references and
therefore attesting its validity as a prediction model.
By the results, it is possible to confirm that the region most
prone to failure during deep drawing is the bottom edge of
the cup, where its fragility is concentrated. It is also possible
to notice a displacement of the failure zone in the direction
of the edge towards the walls of the cup as the coefficient of
friction between the die and the upper surface of the blank
increases.
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