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of Deep-Drawing Process
Jozef Vyboch, Emil Evin, Jozef Kmec
Abstract
In this contribution the results obtained by FEM simulation and experiments are compared. Values of friction
coefficients were experimentally obtained by cup test at change of blankholder pressure and size of blank.
Keywords: formability, FEM simulation, cup test, friction coefficient
1 Introduction
Formability of steel sheets (produceability of stamped
part) depends on material properties (mechanical properties,
microgeometry of contact surfaces), geometry of die and
microgeometry of its contact surfaces, pressure of blankholder, used lubricant, etc. By changing material properties
the change of formability approx. 10-15 % can be obtained,
by changing die geometry about 30-35 %, by changing
friction ratios approx. about 35 %, and other effects can be
obtained by changing sheet thickness, strain speed, etc. 1.
Accurate determination of influence of single parameters on
technological characteristics is problematic, because single
parameters are changed from one case to another and also
their share on formability is changed. To predict the influence of material properties, geometry of die, stamping conditions on sheet formability is possible by simulation methods which enable us to optimise the utilisation of material
properties under concrete conditions. The result of simulation depends on:
- used material model,
- accuracy and completness of simulation software,
- accuracy and completness of material database,
- accuracy and completness of tribological data etc.
(e.g. restricting conditions).
Specialized CAE softwares for simulation of sheet
metal forming processes use the explicit formulation of
FEM for solution of motion equation of equilibrium they
consider non-linear deformation history of sheet and for
description of material behaviour the Hills condition of
plasticity is used :
f
2
r90 . 112 r0 . 22
r90 .r0 . 11 22 2.r45 1
. r90 r0 . 122
2
(1)
r90 .r0 1
where:
r0, r90, r45 are the values of normal anisotropy coefficients
due to rolling direction.
Hardening of material is described by the SwiftKrupkowskys relation. Understanding the deformation history enables us to include the criteria of material damage
(thinning, curve of limiting deformation), creation of wrinkling, pressure on contact surfaces, drawig forces, etc. into
calculation.
By changing friction ratios of material couple sheet
stamping die, the change of material flow can be expessively influenced in such range that the sheet which on the
basis of values of mechanical properties shows unsuitability
to production of concrete stamped part, at application of
suitable lubricant shows required formability in some cases
38
0 .e
. p . T
(2)
where:
0 - reference dynamic viscosity determined at
reference temperature,
- coefficient in dependance on pressure,
- coefficient in dependance on temperature,
p - pressure on contact surfaces,
T - difference between working and reference
temperatures.
Despite the great amount of various research works, for
the state of mixed friction, the dependance of friction coefficient on lubricant properties and stamping conditions has
not been physically described yet. For determination of
friction coefficient for various lubricants and surfaces the
model equipment is used simulators or technological tests
that simulate the stressing of material in real stamping process.
ces of friction coefficient on pressure of jaws were descrybed by following regression models:
material B lubricant FERROCOAT
f B a 0 B . p 0 , 2
(3)
f E a 0 E . p 0,192
(4)
Rp0,2
[MPa]
Rm
[MPa]
C
[MPa]
Rolling
direction
Material
164
299
505
45
172
309
531
0,006
0,23
1,9
0,219
1,5
0,221
2,2
90
166
296
511
168
303
531
0,228
170
292
492
0,208
1,98
45
180
304
503
0,203
1,04
90
184
297
487
0,215
1,59
182
300
497
0,008
0,207
X mean value
For determination of friction coefficient the tester with
parallel jaws and drawing die for cylindrical cups were
used.
On the basis of obtained results by tester the dependan-
Ft 2 Ft1
2.( F p 2 F p1 )
(5)
This relation was determined from condition of equilibrium of forces acting in deep drawing process and also at
the assumption that friction coefficient on contact surfaces
between sheet, blankholder and die is not changed (f1 = f2 =
f3), angle of wrap of the die drawing edge in the moment
of drawing force maximum is equal = /2. Measured values of friction coefficients are given in Fig. 2 and Tab. 3.
Tab. 2 Conditions of experiment
Material of die
Material of blankholder
Material of punch
Diameter of punch with
flat bottom
Radius of die edge of
punch with flat bottom
Radius of die edge of die
Clearance - flat bottom
Sheet metal thickness
Roughness of punch with
flat bottom
Roughness of die
Amount of lubricant
Drawing force
[kN]
Ft1
Ft2
22,4
24
20,5
22,5
Blankholding
force [kN]
Fp1
Fp2
2
10
2
10
Friction
coefficient f
0,104
0,127
39
b) methodics based on comparing the drawing force determined at utilisation of reference lubricant Ftrto drawing
force Ftij determined at utilisation of tested lubricant [1]:
ij
Fij
Ftrj
(6)
f ij
ij 1
1,16 k
speed at materials type DC 05 can be described by dependance of real stress on deformation speed by equation
(7)
where:
k = Fpij / Ftij
Fpij blankholding force,
Ftij drawing force,
Ftrj drawing force at application of reference
lubricant,
i lubricant,
j material.
Then the final friction coefficient is:
f ij f rj f ij
(8)
3 Summary
40
References
Acknowledgement
Presented results have been obtained within research
project, realized in years 2009-2011, financially supported
by Polish Ministry of Science.
Prof. Zbala Wojciech, M.Sc., Dr hab.,
Cracow University of Technology,
Faculty of Mechanical Engineering,
Production Engineering Institute,
Department of Machining and Processes,
al. Jana Pawa II 37, 31-864 Krakw,
Poland,
zebala@mech.pk.edu.pl,
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41