Week 2

1. Fundamentals of
Mechanical
Engineering
Experiments for
Graduate Study
By Numchoak Sabangban
Department of Mechanical Engineering
Khonkaen University
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2. Paper topic reviews
• Die wear in stamping of advanced high strength steels – Investigations on the effects of substrate material and hard-coatings.
• Tribo-characterization of silicon doped and nano-structured DLC coatings by metal forming simulators.
• Cutting performance of Ti–Al–Si–N-coated tool by a hybrid-coating system for high-hardened materials.
• Performance of CrN radical nitride tools on deep drawing of advanced high strength steel.
• Experimental analysis of coating layer behavior of Al–Si-coated boron steel in a hot bending process for IT applications.
• AN EXPERIMENTAL MODELLING AND NUMERICAL FE ANALYSIS OF STEEL-STRIP IRONING PROCESS.
• Prediction of process conditions in drawing and ironing of cans.
• Deep Drawing Analysis of Aluminum Material for Process of Manufacturing Battery Case for Vehicle.
• Finite Element Simulation of Multi-Stage Deep drawing Processes & Comparison with Experimental Results.
• Enhancement of dimple formability in sheet metals by 2-step forming.
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3. Die wear in stamping of advanced high strength steels – Investigations on the effects of substrate
material and hard-coatings.
Authors : Omer NecatiCora, AliAgcayazı a,b, KunioNamiki , HasanSofuoglu , MuammerKoc.
Method and materials :
Using CNC - base wear test setup to find the wear rate of 4 materials coating
(DC 53 + TD, DC 53+Radical Nitriding + TiCN , DC 53 + TiCN , DC 53 + TiC+TiCN+TiN )
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4. Results and conclusions :
From this study the wear rate was shown that the performance of materials
coating.
• The best of wear resistance was a DC 53 + TiCN (PVD) in the CNC slider type wear tester, it
was observed that increased hardness resulted in higher wear resistance as previously
experienced.
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5. Tribo-characterization of silicon doped and nano-structured DLC coatings by metal forming simulators.
Authors : Kuniaki Dohda, Tatsuhiko Aizawa.
Method and materials :
Using DLC (Diamond like carbon 4 type) coating on the die specimen
and find the friction coefficient form
• Prepare the materials coating by CVD (Chemical vapor deposition methods)
• Pin on disc in experiment.
• And keep the data to ironing simulation by using reduction thickness 5%, 10%
and 20%.
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6. Results and conclusions :
The difference coating was shown the difference friction coefficient in this
figure.
• In this study was investigate the COF in the reduction thickness of ironing, that was
shown the minimum COF at the reduction thickness at 5 and 15 percent with Si-DLC
coating.
• Furthermore, this simulation will provide the trend direction for selection of suitable
coating method for prolonging the engineering durability by advancing the DLC coating.
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7. Cutting performance of Ti–Al–Si–N-coated tool by a hybrid-coating system for high-hardened materials.
Authors : Jeong Suk Kim, Gyeng Joong Kim, Myung Chang Kang, Jung Wook Kim, Kwang Ho Kim
Method and materials :
Using AIP (Arc Ion Plating) and high speed cutting to study the relation
ship between tool wear and tool life of Ti – Al – Si –N coating by various spindle
speed.
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8. Results and conclusions :
For the test study the hardness of specimen was increase by Si from
• As the Si content increased, the hardness values of the Ti–Al–Si–N films steeply
increased, and reached a maximum value of approximately 50 GPa at Si content of 9
at.%.
• Tool life of Ti–Al–Si (19 at.%)–N-coated tool in high speed machining was longer than
that of Ti–Al–Si (6 at.%)–N-coated tool due to the self-lubricating tribo layers though its
hardness is lower than the hardness of Ti–Al–Si (6 at.%)–N film.
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9. Performance of CrN radical nitride tools on deep drawing of advanced high strength steel.
Authors : B. Sresomroeng, V. Premanond , P. Kaewtatip , A. Khantachawana , A. Kurosawa , N. Kog
Method and materials :
Find the performance of CrN film coating to reduce scratch during on
ball – on - disc process by evaluate between film coating (CrN, TiN radical Nitride
and CrN radical Nitride), and determine the friction coefficient in deep drawing
process.
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10. Results and conclusions :
Several conclusions can be drawn from the results of the study
• CrN film coating of tools was effective in reducing the friction coefficient in relative
movement with SPFC 980Y material under dry Conditions.
• Radical nitriding before coating of hard thin films increased the bond strength between
the coated film and substrate. Therefore, the radical nitrided tool has a high
performance on deep drawing of advance high strength steel sheet.
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11. Experimental analysis of coating layer behavior of Al–Si-coated boron steel in a hot bending process for
IT applications.
Authors : Yong-Phil Jeon , Hyung-Yoon Seo , Jong-Deok Kim and Chung-Gil Kang
Method and materials :
Using the Al–Si-coated boron steel after the hot bending test to find the
hardness and friction coefficient were tested by a nano-indenter at various positions.
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12. Results and conclusions :
In this contribution, Al–Si-coated boron sheets that
were formed in a hot bending process were investigated by using
EDS–SEM and a nano-indenter
• Different values of the coating layer hardness resulted in
different friction coefficients.
• The blank holding force did not affect the experimental results
significantly.
• Most of the COF was cause by scratching on the coating layer
and the maximum COF was depend on 900 C and blank holder
force at 20 kN.
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13. AN EXPERIMENTAL MODELLING AND NUMERICAL FE ANALYSIS OF STEEL-STRIP IRONING
PROCESS.
Authors : Dragan Adamovic, Vesna Mandic, Zoran Jurkovic, Branko Grizelj,Milentije Stefanovic, Tomislav Marinkovic, Srbislav Aleksandrovic
Method and materials :
Using finite element and experiment of aluminum on U – blending type
in strip reduction ironing and various the reduction angle to estimate the friction
coefficient .
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14. Results and conclusions :
Numerical FE simulation enables the prediction of
important output parameters of the process during deformation,
such as wall tension stress, strain, temperature, ironing force
course etc., in dependence on input parameters (die angle, die
force, friction conditions ).
• In case of reduction degree 5o has been maximum COF on the
punch because in this case the ratio between punch and die
was higher.
• By numerical simulations it is possible to know the distribution
of wall stress in each cross section and the entire sliding path,
as well as to determine deformation forces of ironing process.
• The thickness reduction, die force and COF was increase by
reduction angle
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15. Prediction of process conditions in drawing and ironing of cans.
Authors : Marco Schunemann, Mustafa A. Ahmetoglu, and Taylan Altan
Method and materials :
Using multi pass ironing to investigate the
temperature, wall stress and punch force during the ironing
die and punch stroke.
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16. Results and conclusions :
Numerical FE simulation was shown the similar trend
line to predict the temperature and flow stress
• At the point 1 has been maximum temperature on the first step
of ironing.
• The Aluminum ( AA 303 r =-0.301) was minimum punch force
to forming because that case has a higher temperature
depending on the process.
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17. Deep Drawing Analysis of Aluminum Material for Process of Manufacturing Battery
Case for Vehicle
Authors : J. Y. Kim, K. S. Kim,
Method and materials :
Using sequential forming, it begins with a first
drawing process using raw material that is shaped in an oval
form, followed by the development of the final-shape of the
product in progressive steps involving redrawing and ironing
processes. And find the thickness of finishing part.
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18. Results and conclusions :
Numerical FE simulation was shown the similar trend
line to predict the temperature and flow stress
• The measurement results and thickness change for the
manufactured sample showed that the experimental results for
the thickness distribution along the long and short axes were
similar to those in the analysis results, showing a relative
thickness deviation of approximately 2%.
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19. Finite Element Simulation of Multi-Stage Deep Drawing Processes & Comparison
with Experimental Results.
Authors : A. Pourkamali Anaraki, M. Shahabizadeh, and B. Babaee
Method and materials :
Verify experiment by using finite element to find the
punch force in difference stroke and residual stress in the blank
by chooses the aluminum alloy 7075-O.
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20. Results and conclusions :
Comparison of experimental and FEM simulation results
on the multi-stage drawing process were performed in this study
• Residual stresses are lesser in central area of blank and those are
rising with proceeding in next stages.
• Finite element modeling (FEM) can accurately portray forming
from a particular die design without the need for costly trial and
error. With simulation via FEM, designers can estimate field
variables such as strain distribution, stress distribution, material
flow and forming defects.
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21. Enhancement of dimple formability in sheet metals by 2-step forming.
Authors : Minsoo Kim, Sungsik Bang, Hyungyil Lee, Naksoo Kim, Dongchoul Kim
Method and materials :
Using Zircaloy – 4 type (Anisotropy) in the 2 step
stamping model and validation by FE to find the weak point,
that was cause dimple crack in forming process.
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22. Results and conclusions :
In this study, FE analysis is performed for [only] one
of several dimples but which represents the whole stamping.
• 1-step stamping model cannot be explained by pure bending
since in pure bending, thicknesses are identical before and
after bending,
• the FE solutions are obtain various for the first stamping
tools to find weak point at the edge area, that will be change
the step to forming .
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23. Thank you for attentions
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