Formability Predictions Of Sheet Metal Parts During Product Development Phases
Volume 3 - Issue 6, June 2019 Edition
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Author(s)
Somnath Chavan
Keywords
Sheet metal forming,Product Development cycle, Forming Limit Diagram,Formability Simulations
Abstract
Home appliance industry spends millions of dollars for Formability testing of new developing sheet metal components. Current product Development cycle can be tedious and expensive procedures, particularly when physical prototypes are required on quick basis. When a tangible model is involved, the components must be designed, built, tested, and then fixed accordingly. With Simulation aided development cycle, product moves straight from design to analysis, and then finally to build. Sheetmetal Manufacturing Simulation allows product design teams to view, common defects such as splits, wrinkles, springback and material thinning, all before manufacturing ever takes place. This paper outlines the methodology used for correlation of Sheet Metal parts formability. To validate simulation model, Formability check of freestanding cooktop performed after actual Manufacturing. In Simulation Approach, in order to align well with the exact solution, minute details are taken into consideration such as tonnage and process parameters such as Blank Holder Force, die corner radius, friction coefficient, and die clearance. Simulation methodology results compared with metrology lab data and correlation level analysed. A good correlation was observed from test with simulation data. Correlation levels in Free Standing Range cooktop product had agreement above 94%.The correlation performed with thinning and formability parameters like cracks Or splits, Inadequate stretch. These correlation data points will help organisations to designing new components and digital exploring new design in terms of material variation and geometry variations. This proven model helps to arrive at appropriate decision for selection of optimized and better sheet metal Design.
References
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