The Simulation Analysis on Sheet Metal Deep Drawing Process by Finite Element Method
| Autor: | Cheng-Yu Hsieh, 謝承佑 |
|---|---|
| Rok vydání: | 2014 |
| Druh dokumentu: | 學位論文 ; thesis |
| Popis: | 102 Sheet metal forming technologies have been widely applied in various industries such as automobiles, steel, electronics, shipbuilding, aerospace, and weaponry industries. In this study, finite element method (FEM) and a physical model of stamping die technology were employed to investigate the feasibility of using sheet metal drawing technology and to effectively improve design methods. Drawing is a plastic processing method crucial to sheet forming and a vital component of manufacturing industries. The numerical simulation of sheet forming processes involves an extremely complex system. In traditional sheet forming approaches, the manufacturing cycle time for designing dies is excessively lengthy because substantial time is required to repeatedly undergo die tests. Consequently, the use of sheet forming technologies cannot be sustained, thus increasing the costs and duration of die development. Currently, experts from various industries believe that numerous uncertainties remain in the process of using the deep drawing die forming method. Thus, if development procedures are performed based on only experts’ experiences and no database is established for such procedures, development progresses cannot be determined effectively, which renders satisfying the requirements of industrial operators difficult. With the continual development of computers and computer-aided technologies, deep drawing is gradually applied in the fields of metal plastic forming. In this study, FEM numerical simulation software (PAM-STAMP) was adopted; this software solves relevant problems by integrating sheet metal forming process with a FEM computer simulation technology. This FEM simulation technology was used to study the problems involved in sheet forming, predict and eliminate problems concerning sheet wrinkling and tearing, and reduce or cancel the use of test dies, thereby shortening the durations and lowering the costs of product developments. This study employed PAM-STAMP to analyze and investigate the problems related to sheet metal forming. The results indicated that during sheet drawing, the materials used can be strongly pulled and pushed, and adjusting corner radius R can serve as the medium for controlling material flow. However, R must be appropriately adjusted, where overly high and low R results in rapid material flow and uneven thickness, respectively. Regarding the pushing of deep drawing material, parameters that influence dimensional precision and the smoothness of pushing processes include die friction and die precision. During the process of die design, attention must be paid to the relation and continuity between strip designs, in addition to considering problems related to strip, strip feeding, balance of force, and spring back. Furthermore, effective configuration was applied to complete the overall die design, determine the stripper travel distance, blank lifting height, and punch length, and devise a physical die. After the simple FEM simulation test was performed, the acquired data were integrated with technology parameters required in various processes to perform simulations and actual tests for verifying the feasibility of the developed design. Comparing the simulation findings and actual data showed that the simulation and actual tests yielded consistent result, which further verified the feasibility and reliability of using FEM software in the simulation of sheet drawing. |
| Databáze: | Networked Digital Library of Theses & Dissertations |
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