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Weight reduction of vehicles can be achieved by using high strength steels or aluminum. The formability of aluminum can be improved by applying the forming process at elevated temperatures. A thermo-mechanically coupled material model and shell element is developed to accurately simulate the forming process at elevated temperatures. The use of high...
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... performance of the numerical model, three experiments at room temperature and at elevated temperatures were analysed numerically. In the simulated experiments, the drawing ratio was fixed at 2.09. For this ratio, cups could be drawn at all temperatures, without failure, and the influence of the flange temperature on the thickness can be compared, Fig. 2 and Fig. 3. In Fig. 3, the arc-length is given starting at the outer radius in the transverse direction, continuing to the outer radius in rolling direction and returning to the transvere direction along the outer radius. In Fig. 2, the thickness strain along the rolling direction is given. The influence of the temperature on the ...
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... at all temperatures, without failure, and the influence of the flange temperature on the thickness can be compared, Fig. 2 and Fig. 3. In Fig. 3, the arc-length is given starting at the outer radius in the transverse direction, continuing to the outer radius in rolling direction and returning to the transvere direction along the outer radius. In Fig. 2, the thickness strain along the rolling direction is given. The influence of the temperature on the thickness after the 80 mm punch stroke is most pronounced in the bottom of the cup. An increase in temperature yields a decrease in thickness strain in the bottom of the cup. However, in the simulations, the thickness reduction in the ...
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Citations
... At ESAFORM 2003, Meinders, T., van den Boogaard, A.H., and Huetink, J., [43] presented a paper focusing on forming behavior of alternative materials for the automotive industry. Experiments showed that the drawing ratio of Al-Mg alloys at elevated temperatures could be improved up to the same levels as that of mild steel. ...
Sheet metal forming represents an extensive research area involving numerous topics such as finite element techniques and
modeling, material models, material characterization, formability, component and full-scale test methods as well as a variety
of industrial processes and technologies. In the present overview, however, attempts have been made to mainly concentrate
on recent technology development and innovative sheet metal forming methods, representing a summary of works presented at
ESAFORM conferences during the past decade. The first objective is to demonstrate advances in sheet metal forming by specific
examples with different degree of industrial readiness—from new process ideas to fully industrialized processes. The second
objective is to give a brief discussion on marked and industrial trends, forming the basis and direction for future technology
development and associated research within more basic fields in sheet metal forming.
The formability of two different composite materials used in aerospace industry has been investigated for a representative product geometry. The deformations during forming of carbon UD/PEEK and glass 8HS/PPS blanks with a quasi-isotropic lay-up were analysed. The UD/PEEK product showed severe wrinkling in doubly curved areas, whereas the 8HS/PPS product showed better formability in those areas. This can be explained by the relatively high resistance against intra-ply shear for the UD/PEEK material. Moreover, the predictive capability of a finite element based simulation tool was shown. For both materials, the prediction of intra-ply shear and large wrinkles showed good agreement with those observed in the actual product. The smaller wrinkles in the products cannot be accurately represented with the element size used. However, predicted waviness at the corresponding locations could indicate critical areas in the product. The presented modelling approach shows great potential for application in the composite product design process.
