Failure Analysis of Rapid Prototyped Tooling in Sheet Metal Forming—Cylindrical Cup Drawing

[+] 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), 126-137 (Mar 21, 2005) (12 pages) doi:10.1115/1.1828054 History: Received August 11, 2003; Revised February 11, 2004; Online March 21, 2005
Copyright © 2005 by ASME
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Main effects plot for (a) (σ1)max; (b) (Tn)max
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Influential two-factor interactions for (σ1)max: (a) DR−Rp interaction; (b) t0-Strength interaction; (c) Rd−Wr interaction
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Effects of punch-die clearance and run-off in cup drawing: (a) c=2.25t0; (b) c=1.75t0
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Representative fracture modes: (a) one-crack mode; (b) two-crack mode; (c) three-crack mode
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Progressive formation of die wear after (a) 10 parts; (b) 60 parts; (c) 110 parts; (d) 140 parts
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Plastic deformation in the punch: (a) Rp=3 mm (2 parts); (b) Rp=6 mm (83 parts); (c) Rp=6 mm (413 parts)
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Effect of punch corner radius on normal traction: (a) Normal traction distribution along punch corner; (b) angle around punch corner
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Schematic of deep drawing
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FE model of cylindrical cup drawing
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Stress distributions in the cup drawing die: (a) configuration; (b) maximum principal stress distribution (12.03 sec); (c) minimum principal stress distribution (11.03 sec)
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Force curve for a typical drawing process up to die fracture
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Punch–sheet–die configurations: (a) at maximum drawing force; (b) at fracture
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Stresses along the die corner radius: (a) maximum principal stress curves; (b) definition of “distance”
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A comparison of drawing forces: (a) Case 1; (b) Case 2




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