Search results for "Stamping"
showing 10 items of 42 documents
Design of complex sheet metal forming processes: a new computer aided progressive approach
2010
The growing interest in sheet metal stamping processes, particularly in automotive industry, led to three main issues in this field: request of very complex shapes; growing interest in springback control; solution of multi-objective problems. This makes the design of the sheet metal stamping processes very difficult, since the number of both design variables and design objectives are progressively increased; therefore, proper design methodologies to reduce times and costs are highly required. In this paper, an innovative design approach able to manage and optimize complex stamping operations is proposed. In particular, a progressive design approach based on the integration between numerical…
Shape Distortion and Thickness Distribution during SPIF Processes: Expermental and Numerical Analysis
2011
Single Point Incremental Forming (SPIF) is a quite new sheet forming process which offers the possibility to deform complex parts without dedicated dies using only a single point tool and a standard 3-axis CNC machine. The process mechanics enables strains much higher than traditional sheet forming processes, but particular attention must be given to the final part geometrical accuracy. In this paper the capabilities of a dedicated explicit numerical model are quantitatively analyzed on pyramid-shaped parts. In particular a comparison between experimental and numerical results is reported. Three different shapes at the varying of the stamping angle were considered and the final shape was ac…
The evaluation of springback in 3D stamping and coining processes
1998
Abstract An effective predictive technique of the elastic springback in a fully 3D 90° V-punch V-die bending process is presented. This is based on a combined approach in which an explicit finite element code was used to simulate the loading phase of the process whilst an implicit procedure was used to analyse the springback phase. Two different punches with a nose radius of 4 and 8 mm were used. An increase in the springback ratio with the coining load was observed with the lower nose radius. Conversely, an increase in the springback ratio with the coining load up to a peak value (>1), corresponding to a force of about 20 kN, followed by a decrease in the springback ratio with increasing t…
Springback effect evaluation in three-dimensional stamping processes at the varying of blankholder force
2006
The quantitative evaluation of elastic springback in sheet metal stamping processes is still today a very interesting research topic, since this phenomenon causes a manufacturing shape defect. A measurement technique based on the shadow moiré method, already developed by the present authors, has been further upgraded and applied to evaluate the springback phenomenon in the deep drawing of square boxes, the basic three-dimensional stamping process. In particular this technique is able to determine the final lateral surface of the drawn parts, once extracted from the dies, and to compare such surface with the ideal one derived from the die's computer-aided design (CAD) geometry. Proper quant…
Deep drawing versus incremental forming processes: A comparative cradle to gate analysis
2012
The evaluation and reduction of the environmental impact of manufacturing processes have become a crucial issue in the last few years, addressing the interest of industrial and academic research towards greener solutions and technologies. Reducing input materials and energy requirements has become an imperative action in the industrial practice. As a matter of fact, strong is the concern on lightweight solutions and technologies for sheet stamping operations especially in the automotive sector. However, the knowledge on how impactful such processes are is still poor. In this paper, a comparison between a traditional deep drawing and an single point incremental forming process is investigate…
Analysis of Some Innovative and Flexible Sheet Forming Processes
2002
In the field of sheet forming, innovative and flexible processes that do not impose the use of expensive conventional equipments and/or do not require time consuming set-up operations have become, nowadays, a rather promising research topic. Two different main lines are currently followed: the former is based on the development of new stamping processes based on the utilization of flexible media, while the latter is aimed to develop so called progressive forming processes (spinning and incremental forming). Both hydro-forming and incremental forming permit a very relevant reduction of the tooling and set-up costs and improve process flexibility. These items are discussed in detail in the pa…
An integrated approach to the design of tube hydroforming processes: artificial intelligence, numerical analysis and experimental investigation
2004
In the last years, the growing role of process flexibility in modern mechanical industries has driven a rising interest in optimisation of process/product design through innovative techniques. Moreover, the development of niche productions, which are characterised by low production volumes and small batches leads to the need of more flexible and rapid forming technologies. In this way, a great research effort is performed towards the study of new stamping processes: among them hydro forming finds a large interest in automotive industry since it allows to significantly reduce tooling costs and also to avoid some secondary operations. Different studies are available in the technical literatur…
Incremental forming of friction stir welded taylored sheets
2006
In the last decade sheet metal forming market has undergone substantial mutations since the development of more efficient strategies in terms of flexibility and cost reduction is strictly due. Such requirements are not consistent with traditional metal stamping processes which are characterized by complex equipment, capital and tooling costs; thus the industrial application of such processes is economically convenient just for large scale productions. For this reason most of the research work developed in the last years has been focused on the development of new sheet forming processes able to achieve the above discussed goals. Contemporary, with particular reference to the automotive indus…
Forming of aluminum foam sandwich panels: Numerical simulations and experimental tests
2006
Abstract The forming of the completed aluminium foam sandwich (AFS) panels would determine an improvement in the manufacturing of parts and panels. In this paper the authors have investigated the formability of AFS through experiments and numerical simulations. As far as the former are concerned, commercially prepared panels have been considered and bending and stamping processes have been taken into account. In addition, FEM analyses have been developed, utilizing a porous material model following the evolution of the material density throughout the forming processes.
Investigations on the Mechanical Properties and Formability of Friction Stir Welded Tailored Blanks
2007
Tight competition characterizing automotive industries in the last decades has determined a strong research effort aimed to improve utilized processes and materials in sheet stamping. As far as the latter are regarded light weight alloys, high strength steels and tailored blanks have been increasingly utilized with the aim to reduce parts weight and fuel consumptions. In the paper the mechanical properties and formability of tailored welded blanks made of a precipitation hardenable aluminum alloy but with different sheet thicknesses, have been investigated: both laser welding and friction stir welding have been developed to obtain the tailored blanks. For both welding operations a wide rang…