Effects of Draw-Bending Characteristics on Concave Wall Feature in Rectangular Deep-Drawn Parts

2013 ◽  
Vol 549 ◽  
pp. 92-99
Author(s):  
Wiriyakorn Phanitwong ◽  
Sutasn Thipprakmas
Keyword(s):  
Deep Drawing ◽  
Fem Simulation ◽  
Bottom Surface ◽  
Stress Distributions ◽  
The Finite Element Method ◽  
Deep Draw ◽  
Concave Wall ◽  
Simulation Results ◽  
Draw Bending ◽  
Major Defect

In recent years, the requirements on the complicated deep-drawn parts with the high dimension precision are increasingly. As the major defect, the concave wall feature which commonly encounter in the complicated deep-drawn parts of the difficult-to-deep draw material is focused. In this research, the effects of draw-bending characteristics on concave wall feature during deep-drawing process are clearly identified. The mechanism of concave wall feature related to the draw-bending characteristic was investigated and clearly identified by using the finite element method (FEM) and the experiments were also performed to validate the FEM-simulation results. On the basis of stress distribution, the effects of draw-bending characteristics on the concave wall feature could be clearly identified via the changes of stress distributions on the wall, convex feature and spring-go feature on the bottom surface, and spring-back feature on the top surface. However, comparing with U-draw bending model, the effects of draw-bending characteristics was decreased and the concave wall feature in the case of deep-drawing model was smaller than that in the case of U-draw bending model. The experiments were carried out in both cases of the deep-drawing and U-draw bending models to validate the FEM-simulation results. The FEM-simulation results showed a good agreement with the experimental results with reference to the distribution of material thickness.

Comparison of Offset and Wiping Z-Die Designs for Precision Z-Bent Part Fabrication

2018 ◽  
Vol 140 (2) ◽  
Author(s):  
Sutasn Thipprakmas ◽  
Pakkawat Komolruji ◽  
Wiriyakorn Phanitwong
Keyword(s):  
Fem Simulation ◽  
The Finite Element Method ◽  
Spring Back ◽  
Bend Radius ◽  
Dimensional Precision ◽  
Bending Process ◽  
Simulation Results ◽  
Bend Angles ◽  
Selection Of ◽  
Good Agreement

In recent years, the requirements for high dimensional precision on Z-bent shaped parts have become increasingly stringent. To attain these requirements, the suitable selection of the Z-die bending type has to be considered much more strictly. In this research, two types of Z-bending processes, offset Z-die bending and wiping Z-die bending, were investigated using the finite element method (FEM) to identify the spring-back characteristics and dimensions of Z-bent shaped parts. In the case of offset Z-die bending, the spring-back characteristics on both bend angles were similar. In contrast, in the case of wiping Z-bending, the spring-back characteristics on both bend angles were different. In addition, the dimensions of the Z-bent shaped parts were investigated. It was found, in the case of wiping Z-bending, that web thinning was generated and the outer bend radius was out of tolerance. To validate the FEM simulation results, experiments were carried out. The FEM simulation results showed good agreement with the experimental results in terms of the bend angles and the overall geometry of the Z-bent shaped parts. To achieve precise Z-bent shaped parts, the suitable selection of Z-die bending type in the Z-die bending process is very important.

A Novel Method to Dicing Anodically Bonded Silicon Glass MEMS Wafers Based on UV Laser Technique

2014 ◽  
Vol 511-512 ◽  
pp. 3-7
Author(s):  
Zhi Sheng Jing ◽  
Ze Long Zhou ◽  
Chen Mei ◽  
Xiang Yong Su ◽  
Zhuo Yang ◽  
...  
Keyword(s):  
Thermal Stress ◽  
Bonding Temperature ◽  
Fem Simulation ◽  
Glass Wafer ◽  
Stress Distributions ◽  
Uv Laser ◽  
The Finite Element Method ◽  
Laser Technique ◽  
Novel Method ◽  
Good Agreement

UV laser dicing has many advantages such as mechanical stress-free and dicing shape-free, but it is seldom used to dice multi-layer MEMS wafers because of the deposition of a lot of debris and heat affected zones around the dicing lines. In this paper, a novel UV laser dicing method for anodically bonded wafers is presented. The heat caused split of the bonded silicon and glass around the dicing line is prevented by fabricating recesses on either the glass wafer or the silicon wafer. The Finite Element Method (FEM) in the ANSYSTM software was utilized to analyze the temperature and thermal stress distributions during the dicing process. The thermal stress is minimized sharply due to the fabrication of the recesses beneath the dicing line. The thicknesses of the glass and silicon wafers are 500μm and 250μm, respectively. The anodically bonding temperature is 360oC, and the bonding voltage is 400V. Dicing experiments show that the huge thermal stress caused by the laser can split the originally bonded silicon from glass around the dicing line. After recesses are fabricated along the dicing line, no heat caused split happens. The experiment results are in a good agreement with the FEM simulation. Compared with other methods, this research can provide a more reliable, flexible and cheaper laser dicing process for thick anodically bonded silicon/glass MEMS wafers, especially for multi-layer wafers with free shape.

Study on Hydraulic Deep Drawing of Square Cups

2014 ◽  
Vol 626 ◽  
pp. 334-339
Author(s):  
Te Fu Huang ◽  
Hsin Yi Hsien ◽  
Yan Jia Chen
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
The Finite Element Method ◽  
Experimental Apparatus ◽  
Punch Load ◽  
Simulation Results ◽  
Good Agreement ◽  
Element Method

The friction holding effect and the friction reducing effect occurring during Hydraulic Deep Drawing and the pre-bulging resulting in more plastic deformation on products are applied on sheet hydro-forming. For Hydraulic Deep Drawing of a square cup, the thickness distribution and the relation between the height and the pressure of pre-bulging are simulated with SPCC steels as the specimen by the finite element method. An experimental apparatus of sheet hydro-forming has been constructed to carry out the hydraulic deep drawing experiments of square cups. Experimental thickness distribution and punch load are compared with simulation results. Good agreement was found. The flow patterns of the circular and square blanks with the condition of being firmly pressed against the punch observed from the experiments are in agreement with the predicted results.Keywords:Hydraulic Deep Drawing, sheet hydro-forming, finite element method

FEM Simulation of Metal Drawing Parts Forming Based on the ABAQUS Software

2012 ◽  
Vol 628 ◽  
pp. 123-127
Author(s):  
Zhi Gao Luo ◽  
Jun Li Zhao ◽  
Xu Dong Li ◽  
Jing Jing Zhang ◽  
Ying Qing Shao
Keyword(s):  
Deep Drawing ◽  
Metal Forming ◽  
Fem Simulation ◽  
Forming Process ◽  
Modeling And Analysis ◽  
Software Simulation ◽  
Metal Stamping ◽  
Simulation Results ◽  
Changes Over Time ◽  
Abaqus Software

In this paper, metal stamping deep drawing forming process was simulated by Abaqus software. first of all, metal deep drawing forming for finite element modeling and analysis. Then the simulation results of drawing parts metal forming were analyzed. Include the analysis of stress-strain changes over time and the most serious regional. To determine the position easy to crack in the process of metal drawing parts stamping. Finally, by stamping test to verify the position of the cracks by punching test whether compliance with the simulation results. Verify the accuracy of the Abaqus software in the process of stamping simulation. Verify the accuracy of the Abaqus software simulation in metal forming processes.

Numerical Analysis and Simulation (FEM) of a Double Deep Drawing Sink Height

2017 ◽  
Author(s):  
Pedro de Jesús García Zugasti ◽  
Hugo Iván Medellín Castillo ◽  
Pablo Alberto Limon Leyva ◽  
Eder Hazael Govea Valladares ◽  
José Luis Hernández Rivera
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Experimental Methods ◽  
Height Increment ◽  
The Finite Element Method ◽  
Steel Material ◽  
Simulation Results

This paper presents the results of a research project obtained using theoretical, numerical and experimental methods, in order to solve the problems encountered when increasing the height of a double deep drawing sink, and the proposed solution. The analysis considers: Manufacturer limitations (eg. tool modifications, steel material changes etc.), the process parameters observed and measured during the deep drawing operation of the failure part, the theoretical fundamentals of sheet metal forming and the analysis and simulation with a computer program based in the finite element method (FEM). The analysis and simulation results using a FEM program showed that, it is possible the height increment of the sink, utilizing a variable blankholder force, to an 11% above from the fabricated parts before the application of the proposed solution but 5% less than the required final product height.

Research of Force in Piercing Process by FEM Simulation

2012 ◽  
Vol 482-484 ◽  
pp. 62-65 ◽  
Author(s):  
Lu Lu ◽  
Zhao Xu Wang ◽  
Fu Zhong Wang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Numerical Methods ◽  
Fem Simulation ◽  
Dynamic Evolution ◽  
Physical Parameters ◽  
The Finite Element Method ◽  
Simulation Results ◽  
The Stability ◽  
Future Plans

In this paper, the finite element method (FEM) is used for simulation of piercing process of the tube in Mannesmann mill. The sensitivity of the simulation results to numerical methods and physical parameters is discussed. The simulated results visualize dynamic evolution of force in the piercing process. The stability of the process and force condition is analyzed by FEM simulation. The model is verified by comparing the values of calculated force parameters and those measured in laboratory conditions. Finally, the future plans are presented.

Investigation Mechanism of V-Ring Indenter Geometry in Fine-Blanking Process

2009 ◽  
Vol 410-411 ◽  
pp. 305-312 ◽  
Author(s):  
Sutasn Thipprakmas ◽  
Masahiko Jin
Keyword(s):  
Hydrostatic Pressure ◽  
Material Flow ◽  
Crack Formation ◽  
Fem Simulation ◽  
Great Difficulty ◽  
The Finite Element Method ◽  
Fine Blanking ◽  
Simulation Results ◽  
Blanking Process ◽  
Indenter Geometry

The V-ring indenter geometry (angle, height and position) was investigated by using the finite element method (FEM) to theoretically clarify the mechanism and its action in the fine-blanking process. The FEM simulation results indicate that very small or very large V-ring indenter angles, heights, and positions cause difficulty in the rotation of the material-flow and that the hydrostatic pressure is generated with great difficulty in the blanked material; therefore, crack formation occurs easily. The application of a suitable V-ring indenter angle, height, and position significantly suppresses the formation of rotating flow, which results in increased hydrostatic pressure, and crack formation is consequently prevented.

Study on Simulation and Experiment of Micro Sheet Metal Forming

2014 ◽  
Vol 941-944 ◽  
pp. 1876-1881 ◽  
Author(s):  
Yue Zhao ◽  
Liang Luo ◽  
Zheng Yi Jiang ◽  
Xiao Ming Zhao ◽  
Di Wu
Keyword(s):  
Deep Drawing ◽  
Fem Simulation ◽  
Drawing Process ◽  
The Finite Element Method ◽  
Micro Forming ◽  
Forming Process ◽  
Deep Drawing Process ◽  
Manufacturing Method ◽  
Micro Deep Drawing ◽  
Simulation And Experiment

In the last few decades, there is a global interest in micro products, and micro forming of metals is a promising micro manufacturing method. However, a comprehensive understanding of this process is absent. Therefore, this study aims to investigate micro deep drawing process via experimental and analysis work. Simulation results are in good agreement with the experimental data. The comparison between the finite element method (FEM) simulation and experimental results shows the feasibility of FEM simulation for micro deep drawing process. This research also lays a fundament of investigating micro forming process, especially micro deep drawing.

The Prediction of Earing and the Design of Initial Shape of Blank in Cylindrical Cup Drawing

2006 ◽  
Vol 532-533 ◽  
pp. 865-868 ◽  
Author(s):  
Tung Sheng Yang ◽  
Yuan Chuan Hsu
Keyword(s):  
Finite Element ◽  
Deep Drawing ◽  
Fem Simulation ◽  
Drawing Process ◽  
The Finite Element Method ◽  
Element Analysis ◽  
Initial Shape ◽  
Blank Holder ◽  
Cylindrical Cup ◽  
Cup Drawing

The parameters such as aniotropic property, blank holder force and friction coefficient between tool and blank are not only effect on the forming force, stress and strain distribution of the worpiece, but also on the earing in products. In this paper, the finite element method is used to investigate the earing of the deep drawing process. In order to verify the prediction of FEM simulation of the earing in the cylindrical cup drawing process, the experimental data are compared with the results of the current simulation. A finite element analysis is also utilized to reduce the earing profile of the drawn products, a reverse forming method for obtaining the initial blank’s shape according to the forward cup deep drawing simulation is proposed.

Effect of Draw Bead Height on Wall Features in Rectangular Deep-Drawing Process Using Finite Element Method

2011 ◽  
Vol 264-265 ◽  
pp. 1580-1585 ◽  
Author(s):  
Sutasn Thipprakmas
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Tensile Stress ◽  
Fem Simulation ◽  
Bead Geometry ◽  
Concave Wall ◽  
Convex Wall ◽  
Simulation Results ◽  
Bead Height ◽  
Element Method

Concave/convex wall features are usually generated in the deep-drawn parts with complicated geometry, especially the difficult-to-deep draw materials. The application of the draw bead could reduce the concave/convex wall features. However, it is difficult to determine the suitable draw bead geometry and its position to obtain a straight wall. In this study, the effects of draw bead height were investigated using the finite element method (FEM) and experiments. The application of the draw bead and the effects of its height on the concave/convex wall features could be theoretically clarified on the basis of principal stress distribution. The application of draw bead led to the decrease in tensile stress in the direction of punch movement and also increased in the tensile stress distributed to the corner zone; therefore, the concave wall feature decreased. In addition, this feature decreased as the draw bead height increased. However, the application of a very large draw bead height resulted in a convex feature. The FEM simulation results were validated by experiments in the following two cases, i.e., without and with draw bead formations. With reference to the material thickness distribution, the FEM simulation results showed a good agreement with experimental results.

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