Shear dominated deformation with curved beaks in folding-shearing.

IF 2.9 3区 工程技术 Q2 AUTOMATION & CONTROL SYSTEMS
Rishabh Arora, Omer Music, Julian M Allwood
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引用次数: 0

Abstract

The deep drawing process in the automotive industry generates up to 45% material waste. To address this issue, the folding-shearing process was developed as a drop-in solution, enabling the formation of parts in pure shear with minimal thickness variation. This process involves folding a blank while collecting the excess material in a region called the 'beak', which is subsequently sheared in-plane using a single set of tools moving in one forming direction. This paper investigates the extent to which the curvature of the geometry of the beak influences the resulting thickness distribution. A combination of physical and numerical trials demonstrates that a beak design with a negative Gaussian curvature reduces the maximum thickening by 65%. This reduction in thickening helps minimise the forming loads and tool wear, thereby improving the overall robustness of the process. An analytical model is proposed to predict the resulting thickness distribution and demonstrates accuracy within a 12.5% deviation from experimental results. Finally, a design map is proposed to instantly identify the optimal beak design parameters without the need for extensive numerical or physical validations while ensuring a minimal thickness change.

褶皱-剪切变形以剪切为主,喙部弯曲。
汽车工业的深拉深工艺产生高达45%的材料浪费。为了解决这个问题,折叠-剪切工艺被开发为一种插入式解决方案,使零件在最小厚度变化的情况下形成纯剪切。这个过程包括折叠空白,同时在一个称为“喙”的区域收集多余的材料,随后使用一套工具在一个成型方向上移动,在平面内剪切。本文研究了在多大程度上,曲率的几何喙的影响产生的厚度分布。物理和数值试验相结合表明,具有负高斯曲率的鸟嘴设计可使最大增厚降低65%。这种增厚的减少有助于最大限度地减少成形负荷和工具磨损,从而提高工艺的整体稳健性。提出了一种分析模型来预测得到的厚度分布,其精度与实验结果的偏差在12.5%以内。最后,提出了一个设计地图,以立即确定最佳的喙设计参数,而不需要广泛的数值或物理验证,同时确保最小的厚度变化。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
CiteScore
5.70
自引率
17.60%
发文量
2008
审稿时长
62 days
期刊介绍: The International Journal of Advanced Manufacturing Technology bridges the gap between pure research journals and the more practical publications on advanced manufacturing and systems. It therefore provides an outstanding forum for papers covering applications-based research topics relevant to manufacturing processes, machines and process integration.
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