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




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