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Research Papers

Modeling and Analysis of the Process Energy for Cylindrical Drawing

[+] Author and Article Information
Lei Li

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: hfut_lilei@hotmail.com

Haihong Huang

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: huanghaihong@hfut.edu.cn

Fu Zhao

School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907-2088;
Environmental and Ecological Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: fzhao@purdue.edu

Xiang Zou

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: xiangzouhfut@163.com

Gamini P. Mendis

Environmental and Ecological Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: gmendis@purdue.edu

Xiaona Luan

School of Mechanical Engineering,
Shandong University,
Jinan 250061, China;
Key Laboratory of High-efficiency and Clean
Mechanical Manufacture (Ministry of Education),
Shandong University,
Jinan 250061, China
e-mail: xiaona0412@126.com

Zhifeng Liu

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: zhfliuhfut@126.com

John W. Sutherland

Environmental and Ecological Engineering,
Purdue University,
West Lafayette, IN 47907-2088
e-mail: jwsuther@purdue.edu

1Corresponding author.

Manuscript received February 27, 2018; final manuscript received November 4, 2018; published online December 24, 2018. Assoc. Editor: Karl R. Haapala.

J. Manuf. Sci. Eng 141(2), 021001 (Dec 24, 2018) (13 pages) Paper No: MANU-18-1124; doi: 10.1115/1.4041924 History: Received February 27, 2018; Revised November 04, 2018

As energy efficiency increases in importance, researchers have identified manufacturing processes as opportunities where energy consumption can be reduced. Drawing is one widely employed, energy intensive manufacturing process, which could benefit by analysis of energy consumption during operation. To optimize the energy consumption of the drawing process, this paper developed an explicit model to quantify the process energy for the cylindrical drawing process by analyzing the dynamic punch force during the process. In this analysis, the evolution of the stress and strain was analyzed in the drawn part by considering all the structure parameters of the drawn part. The stress and strain analyses were integrated into an overall process energy model, and the behavior of the model was classified into three categories, based on their physical mechanisms, i.e., deformation energy, bending energy, and friction energy. The model was validated using numerical experiments designed by the Taguchi method where two different kinds of materials were tested over 18 runs. The results from the numerical experiments were compared with those from the model, and show that the maximum variation of the process energy predicted by this model is less than 10% for a given part. Sensitivity analysis was performed on the model to understand the contributions of the process parameters on the process energy to guide process optimization for lower energy consumption. The established model can assist in the rapid design of drawn parts with lower embodied energy.

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Figures

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Fig. 1

Distribution of energy consumption in a drawing process

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Fig. 2

Distribution of energy consumption in an improved drawing process using the multi-equipment sharing strategy

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Fig. 3

Schematic of the drawing process and equipment systems for a cylindrical part

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Fig. 4

Regions with different strain state in a drawn part

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Fig. 5

Stresses acting on the flange region during drawing (E and F are the corresponding points in Fig. 4)

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Fig. 6

Infinitesimal element and stress acting on the die shoulder. (a) The stress state of the infinitesimal element from term one and (b) surface of region II in three-dimensional coordinates.

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Fig. 7

Bending and unbending stress around the die shoulder

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Fig. 8

Infinitesimal element and stress (b) acting on the slope region (a)

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Fig. 9

Schematic of geometrical diagram during the drawing process

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Fig. 10

Model employed in the simulation: (a) three-dimension model and (b) the finite element model with meshing grid

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Fig. 11

Material characteristics (true stress–strain curves) employed in the simulation

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Fig. 12

Variation of process energy changes with the maximum thickness variation

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Fig. 13

Distribution of the experimental Taguchi runs

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Fig. 14

Percentage changes on process energy when positive and negative changes occur in all the parameters for MA1 (a) and MA2 (b)

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Fig. 15

Process energy allocation in three different parts for MA1 (a) and MA2 (b)

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Fig. 16

The interactions between the three dimensions (parameters, forming quality, and electrical energy) and the forming equipment

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