0
TECHNICAL PAPERS

Failure Analysis of Rapid Prototyped Tooling in Sheet Metal Forming—V-Die Bending

[+] Author and Article Information
Y. Park, J. S. Colton

The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405

J. Manuf. Sci. Eng 127(1), 116-125 (Mar 21, 2005) (10 pages) doi:10.1115/1.1828053 History: Received August 11, 2003; Revised February 11, 2004; Online March 21, 2005
Copyright © 2005 by ASME
Your Session has timed out. Please sign back in to continue.

References

Park, Y., 2003, “Sheet Metal Forming Using Rapid Prototyped Tooling,” Ph.D. thesis, Georgia Institute of Technology.
Nakagawa,  T., 2000, “Advances in Prototype and Low Volume Sheet Forming and Tooling,” J. Mater. Process. Technol., 98, pp. 244–250.
Soar, R., Arthur, A., and Dickens, P., 1996, “Processing and Application of Rapid Prototyped Laminate Production Tooling,” Proceedings of the 2nd National Conference on Rapid Prototyping and Tooling Research, pp. 65–76.
Du,  Z. H., Chua,  C. K., Chua,  Y. S., Loh-Lee,  K. G., and Lim,  S. T., 2002, “Rapid Sheet Metal Manufacturing. Part 1: Indirect Rapid Tooling,” Int. J. Adv. Manuf. Technol., 19, pp. 411–417.
Cheah,  C. M., Chua,  C. K., Lee,  C. W., Lim,  S. T., Eu,  K. H., and Lin,  L. T., 2002, “Rapid Sheet Metal Manufacturing. Part II: Direct Rapid Tooling,” Int. J. Adv. Manuf. Technol., 19, pp. 510–515.
Walczyk,  D. F., and Hardt,  D. E., 1998, “Rapid Tooling for Sheet Metal Forming Using Profiled Edge Laminations—Design Principles and Demonstration,” ASME J. Manuf. Sci. Eng., 120, pp. 746–754.
Altan,  T., and Vazquez,  V., 1996, “Numerical Process Simulation for Tool and Process Design in Bulk Metal Forming,” CIRP Ann., 45, pp. 599–615.
Knoerr,  M., Lange,  K., and Altan,  T., 1994, “Fatigue Failure of Cold Forging Tooling: Causes and Possible Solutions through Fatigue Analysis,” J. Mater. Process. Technol., 46, pp. 57–71.
Hettig, A., Reiss, W., and Lange, K., 1989, “A Study of Tool Fracture in Cold Extrusion,” Transactions of NAMRI/SME, XVII , Columbus, OH, pp. 49–53.
Knoerr, M., Lange, K., and Altan, T., 1992, “An Integrated Approach to Process Simulation and Die Stress Analysis in Forging,” Transactions of NAMRI/SME, XX , Pullman, WA, pp. 53–60.
Geiger,  M., Hansel,  M., and Rebhan,  T., 1992, “Improving the Fatigue Resistance of Cold Forging Tools by FE Simulation and Computer Aided Die Shape Optimization,” IMechE, Part B: J. of Eng. Manuf., 206, pp. 143–150.
Kalpakjian, S., 1997, Manufacturing Processes for Engineering Materials, 3rd ed., Addison-Wesley, Menlo Park, CA.
Suchy, I., 1998, Handbook of Die Design, McGraw-Hill, New York, NY.
American Society of Tool and Manufacturing Engineers, 1965, Die Design Handbook, 2nd ed., McGraw-Hill, New York, NY.
Cser,  L., and Geiger,  M., 1991, “A Generalized Life Time Model for Cold Extrusion Tools,” CIRP Ann., 40(1), pp. 299–301.
Bannantine, J. A., Comer, J. J., and Handrock, J. L., 1990, Fundamentals of Metal Fatigue Analysis, Prentice–Hall, Englewood Cliffs, NJ.
Suresh, S., 1998, Fatigue of Materials, Cambridge University Press, Cambridge, UK.
Smith,  K. N., Watson,  P., and Topper,  T. H., 1970, “A Stress–Strain Function for the Fatigue of Metals,” J. Mater., 5(4), pp. 767–778.

Figures

Grahic Jump Location
V-die bending terminology 12
Grahic Jump Location
Finite element model of V-die bending
Grahic Jump Location
Paths leading to tool failure 15
Grahic Jump Location
Bottom crack induced by punch overload and critical stresses
Grahic Jump Location
Propagation of critically stressed region: (a) Punch over-travel Δdp=0.32 mm; (b) punch over-travel Δdp=0.73 mm
Grahic Jump Location
Strain gauge locations and measurement orientations
Grahic Jump Location
Experimental setup for V-die bending
Grahic Jump Location
Punch-blank-die configuration in a typical V-die bending: (a) Geometric representation; (b) maximum principal stress distribution
Grahic Jump Location
Top view of “V” surface of the die after 1000 stamping cycles
Grahic Jump Location
Flexure S-N data for Ren Shape™ 5166 1: (a) zero-to-tension; (b) fully reversed
Grahic Jump Location
A comparison of stress ratios of various damage parameters
Grahic Jump Location
Failure modes in a V-bending die: (a) fatigue failure; (b) fracture due to overload

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In