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Research Papers

Using Servo-Drive Presses to Determine the Effect of Blank Holder Pressure on Temperature Change in Warm Forming of Sheet

[+] Author and Article Information
Serhat Kaya

Department of Automotive Engineering, Atilim University, Ankara, 06836, Turkey; Engineering Research Center for Net Shape Manufacturing (ERC/NSM),  The Ohio State University, Columbus, OH 43210

J. Manuf. Sci. Eng 133(6), 061024 (Dec 27, 2011) (6 pages) doi:10.1115/1.4005457 History: Received October 26, 2010; Revised November 11, 2011; Published December 27, 2011; Online December 27, 2011

Heat transfer coefficient (HTC) is one of the most important and difficult-to-obtain parameter in high temperature environment. Contact pressure and workpiece surface roughness are among important parameters that affect the heat transfer in elevated temperature forming of sheets. In this study, HTCs are investigated experimentally by using a servo-drive press. With the flexibility that the servo-drive press offers, effect of various blank holder pressures on temperature change is determined. Before and after surface roughness conditions of aluminum and magnesium (from two different manufacturers) alloy sheets are compared. Experimental setup was modeled using deform 2d, and measured temperature curves were compared with the finite element analysis (FEA) predictions and a window of heat transfer coefficients were determined for warm forming of sheets. Determined heat transfer coefficients were implemented in a nonisothermal deep drawing FE model in deform 2d and results were compared with experiments. Good agreement was obtained between FEA predictions and experiments.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

The flexibility of slide motion in servo-drive (or free motion) presses [4]

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Figure 2

Schematic view of nonisothermal deep drawing process sequence

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Figure 3

Servo-drive press motion curves for warm forming

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Figure 4

Open warm forming tooling (bottom die set on the left, top die set on the right, punch diameter: 40 mm, punch radius: 4 mm, die radius: 6 mm)

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Figure 5

Top view of the fixture used to record temperature

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Figure 6

Schematic view of the experimental setup and FE model

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Figure 7

Measured and calculated temperature–time curves

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Figure 8

Ra values of Al 5052-H32

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Figure 9

Ra values of Mg AZ31-O (supplier A) and Mg AZ31-O (supplier B)

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Figure 10

BHP—Dome height at T = 300 °C

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Figure 11

Change in sheet diameter with respect to BHP (sheet diameter: 100 mm)

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Figure 12

Comparison of punch load predictions using various heat transfer coefficients (kW/m2 C) with experiment

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Figure 13

Predicted thickness distribution comparison with various heat transfer coefficients (kW/m2 C)

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