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Prakash J. Banait
Head Application NRB Bearings Ltd. 2nd Pokhran Rd.,Thane 400 610
Sohail Shaikh
Sr. Engineer NRB Bearings Ltd. 2nd Pokhran Rd.,Thane 400 610 St.salunke@nrbbearings.co.in
Suresh T. Salunke
Head Engineering NRB Bearings Ltd. 2nd Pokhran Rd.,Thane 400 610
Abstract: The process of new product development through sheet metal forming is one of the most common manufacturing processes existing in industries; however it is not easy to design the process and the tools for most of the components. Material breakage, wrinkling, shape defects, cracks are the defects encountered in sheet metal forming operation. Such defects can be foreseen during die development using HyperForm and Radioss forming simulation technique, and through simple design change their occurrence can be prevented during manufacturing. The paper converses the integration of sheet forming simulation in the tool surface development and process development phase. It discusses about the different results obtained from the simulation which help to derive the solution if the component fails during forming. Virtual tryouts results in reduction of time and cost. It is helpful in deciding the tonnage, geometry and the material properties of the product to design the manufacturing process effectively.
Introduction:
Sheet metal forming involves complicated deformation process with material, geometrical and contact non linearity. For obtaining the optimized design of such forming processes investigations into the details of deformation, formation of wrinkles stretching and cracks are extremely important. In industry many physical try outs are carried out by making prototypes using thumb rules and empirical formulae to find right manufacturing parameters by trial and error. Based on the results obtained from the tryouts, the parameters are altered until the best result is obtained. This approach is time consuming and expensive and calls for metal forming simulation. The primary objective of the sheet metal forming simulation: 1) 2) 3) 4) Predict the metal flow Check the feasibility of producing parts without flaws Optimize and freeze the tool design Optimize the process parameters.
The glory of forming simulation is that it does so in the virtual world before the tool is actually built. Solutions to the various problems are diagnosed prior to manufacturing and can be rectified in short time. Forming simulation often called as virtual manufacturing can be used to see all the desired outputs from a forming operation such as thinning, wrinkles, stretching, cracks, etc.
Process methodology:
Blank Component The sleeve shown in the above figure is manufactured by a series of the forming and the cutting process. Process flow for Sleeve manufacturing:
Blank
First Cupping
Second Cupping
Third Cupping
Final Component
Collar Cutting
Bottom Cutting
Calibration
Material Properties:
First Cupping:
The assembly set up for the first cupping is shown in the figure below. The blank is given the specified material properties, the components are meshed considering the sheet metal geometry, displacement and curvature. Areas of metal flow and curvature are meshed critically.
Punch
Blank
Blank Support
Die
Formability diagram shows the areas of the compression and the risk of cracks and wrinkles generated during the first cupping.
The maximum tonnage reported for first cupping in HyperForm for first cupping is 25485N.
Second Cupping:
Punch
DIE
The maximum tonnage reported for first cupping in HyperForm for second cupping is 66657N
Third Cupping:
Punch
DIE
The maximum tonnage reported for first cupping in HyperForm for third cupping is 29662.3N
Calibration:
Punch
DIE
The maximum tonnage reported for first cupping in HyperForm for calibration as shown in the simulation will be 591834.5N
Benefits Summary
Challenges:
The co relation between the inputs like friction, material properties and the actual try out condition is difficult. Actual testing of material is required whenever new grade is to be tried out. Optimization of the solving time and accuracy level to be established and used Improvement in the software to automate the set up when the geometry changes required are frequent.
Conclusion:
In todays scenario of latest new product development trends, where the time to introduce a new product is under pressure, forming simulation for each sheet metal component has become essential. Sheet metal simulation help the tool designer to understand metal flow in a better way for complex shapes, which in turn increases the component quality and reduce the design cycle time and cost. It can be effectively used for optimizing the die design in order to improve quality, optimizing process parameters without any physical tool build. ACKNOWLEDGEMENTS The authors would like to thank NRB management especially Mr. S T Salunke, G.M. Engineering for his sustained motivation and support throughout the project. In the end, the authors would like to thank Altair and design tech team for their invaluable guidance and focus on the completion of this project.
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