Combined method for die compensation in sheet metal forming
Sheet metal forming is one of the prominent methods to convert blank sheet material into a product. In sheet metal forming, proper allowance of its tools must be given to the elastic recovery, due to the nature of elastic property which is called springback. When stamped sheet components are remo...
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| Main Author: | |
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| Format: | Thesis |
| Language: | English English |
| Published: |
2014
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| Subjects: | |
| Online Access: | http://eprints.uthm.edu.my/1211/1/24p%20AGUS%20DWI%20ANGGONO%20MUHAMMAD%20MARHABAN.pdf http://eprints.uthm.edu.my/1211/2/AGUS%20DWI%20ANGGONO%20MUHAMMAD%20MARHABAN%20WATERMARK.pdf |
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| Summary: | Sheet metal forming is one of the prominent methods to convert blank sheet
material into a product. In sheet metal forming, proper allowance of its tools
must be given to the elastic recovery, due to the nature of elastic property which
is called springback. When stamped sheet components are removed from the
forming tools, the internal stresses will rest, and a new equilibrium state will
be reached. As a result, the final shape of the drawn part will deviate from
the shape imposed by the forming tool. Therefore, it is very important that
springback be accurately predicted and compensated. In the industry, this is a
costly and time consuming process of product shaping and redesigning the tools
manually. The goal of this research is to develop a compensation procedure that
can perform this optimization process, using the combination of Displacement
Adjustment (DA) and Spring Forward (SF) methods. Both are based on an
iterative procedure. The method is needed for guiding die design to compensate
for springback in a backward direction and then to compensate springback in a
forward direction. This new approach is then called Combined Method for Die
Compensation (CMDC). The testing of CMDC has been conducted in 2D model
of U-bending and 3D shape of S-rail model adopted from Numisheet 2008. The
result shows that CMDC is able to reduce error in every cycle of the total five
cycles. The result of reduction in shape deviation is 66% to 73% for the 2D
model compensation, and for the 3D model, 55% reduction in shape deviation
can be reached. The CMDC method can be further implemented and integrated
in a commercial FEM software to assist the optimization process to improve the
precision of stamping products. |
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