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Shock Tube Based Forming of Sheets
Published in Kakandikar Ganesh Marotrao, Anupam Agrawal, D. Ravi Kumar, Metal Forming Processes, 2023
Saibal Kanchan Barik, R. Ganesh Narayanan, Niranjan Sahoo
Further, AA 5052-H32 sheet has been stretched to failure in order to study the increase in the forming limits during the high-velocity shock tube experiments. The distribution of failure strains for both high-speed forming and quasi-static forming have been compared and observed a considerable improvement in the formability during shock tube based forming (Figure 2.11). The increase in the formability is due to the inertial forces involved with the process, which help the material to avoid sharp local velocity gradient on the material surface, allowing it to stretch further without strain localization.
Improvement in Forming Characteristics Resulted in Incremental Sheet Forming
Published in Kishor Kumar Gajrani, Arbind Prasad, Ashwani Kumar, Advances in Sustainable Machining and Manufacturing Processes, 2022
Saurabh Thakur, Parnika Shrivastava
To quantify the ISF process formability, geometrical accuracy and surface finish have been readily used throughout the literature. Formability, in the conventional sheet metal–forming process, is the ability of the metal to deform without failure. In ISF, however, the plastic zone is restricted to the small area of contact between the tool and the workpiece, and formability is quantified using the maximum forming or draw angle; sometimes, the depth of forming has also been used to measure the formability [7]. Draw angle is the largest angle of deformation in one pass of the tool without tearing of the sheet metal [4]. Some of the early research aimed at obtaining forming-limit curves (FLCs) for the process to compare it to the traditional sheet metal–forming process. Figure 16.1 shows FLC for the ISF process in contrast to the conventional forming process in major and minor strain space for an aluminum sheet [8]. Formability, as defined by the formability limit curve, was a straight line with a negative slope.
Advances in Sheet Metal Stamping Technology: A Case of Design and Manufacturing of a Car Door Inner Panel Using a Tailor Welded Blank
Published in Pankaj Agarwal, Lokesh Bajpai, Chandra Pal Singh, Kapil Gupta, J. Paulo Davim, Manufacturing and Industrial Engineering, 2021
Tushar Y. Badgujar, Satish A. Bobade
The joining (welding) is performed prior to forming of components. At the time of forming TWB, it is required to optimally distribute the material in order to achieve strength and cost optimisation. Ideally, the uniform distribution of material is significant (Badgujar and Wani 2018). Development with TWB means a lighter panel, high strength and welding before forming results in a reduction of production cost (Merklein et al. 2014; Dabhi, Thanki, and Patel 2014; Kinsey and Wu 2011). In the forming of the TWB, the formability of material plays a significant role. The formability of sheet metal depends on the thickness of the aforementioned sheet metal, its microstructure and external factors. Formability is the ease with which a given sheet of any material can be formed. The forming of sheet metal takes place due to plastic deformation achieved by mechanical means. A typical set-up consists of a platform and tooling is used where sheet metal is forced by a punch to get the shape of the die. The formability of sheet metal can be measured using several techniques (Gaied et al. 2009).
Sheet metal shrink flanging process: a critical review of current scenario and future prospects
Published in Materials and Manufacturing Processes, 2023
Formability is one of the most important and vital issues in sheet metal forming processes. During an experimental investigation of stretch forming process, it is found that flow stress of precipitate-hardenable Inconel 718 superalloy was severely influenced by increment in temperature and in strain rates as well [329]. In another case of electro hydraulic forming, formability is also investigated [336]. Formability of aluminum alloys 5052 sheets was found to be increased by 45–50% in terms of limiting strains in all three regions of forming limit diagram due to electro-hydraulic forming as when compared to conventional forming[336]. Necking also seems to be absent prior to failure due to electro-hydraulic forming [336]. In another attempt of electromagnetic forming of Ti-6Al-4 V titanium alloy, a substantial increment has been observed due to high velocity and high strain rate forming as compared to the quasi-static condition of forming [352].
A review on experimental and numerical studies on micro deep drawing considering size effects and key process parameters
Published in Australian Journal of Mechanical Engineering, 2022
Satish Chinchanikar, Yash Kolte
The size of the part significantly affects the process behaviour even if the relationship between the main geometrical features is kept constant. Tribological size effects must be considered while designing MDD as the friction coefficients increase significantly with decreasing process dimension (Hu 2011). Density, shape and microstructure type of size effects also influence the flow stress of a material. It is reported that the formability decreases with a decrease in grain size and with the increase in the grain size to thickness ratio. Size effects influence the forming forces, springback, the dimensional and shape accuracies of the parts (Vollertsen et al. 2009).
Experimental and numerical study of telescopic conical energy absorber under inversion process
Published in Mechanics Based Design of Structures and Machines, 2023
Sajad Azarakhsh, Mohammad Javad Rezvani, Adel Maghsoudpour
Rosa, Rodrigues, and Martins (2006) conducted a comprehensive analytical and experimental study on thin-walled tubes with an inversion process. They found that the range of formability was strongly influenced by frictional boundary conditions and lubrication plays an important role in the overall success of the invert-forming operation. Gupta (2011) presented an experimental and computational study on the inversion process of the thin-walled conical tubes with optimize the semi-apical angle to get a constant collapse load and development of the inversion mode. It concluded that the semi-apical angle of the conical tube should be between 8° and 11° to obtain a constant collapse load and steady load–displacement curve during their inversion process of collapse. Liu, Qiu, and Yu (2018) proposed a theoretical model of the inversion for circular metal tubes compressed over a conical die, to predict the compressional force and the final tubular radius. Also, they discussed the influence of the die radius, friction between the die and tube, as well as the dynamic effect. Magrinho, Centeno, Silva, Vallellano, et al. (2019) combined new techniques and methods based on digital image correlation and wall thickness measurements to obtain new and useful insights into the various deformation processes of external tube inversion. They found that very small axial displacement and a high amount of energy absorption occurred in die fillets with a small radius. Also, die fillets having large radii were giving controlled crashworthiness parameters. In addition, medium-size radius of the die fillet was found to be giving efficient results in terms of all crashworthiness parameters. Chahardoli, Shabanzadeh, and Marashi (2022) introduced a new type of energy absorber, where the energy is absorbed through a quasi-static process including a combination of inversion and folding. This absorber is composed of a frustum tube and a cylindrical serving as a lightweight thin-walled mandrel. The collapse process began with inverting the frustum followed by the simultaneous collapse of the inverted frustum and the cylindrical tube. Experimental results showed that the proposed absorber could enhance the specific energy by 26%, as compared to the conventional absorbers.