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Research Papers

An Automated Process Sequence Design and Finite Element Simulation of Axisymmetric Deep Drawn Components

[+] Author and Article Information
Ali Fazli

Mechanical Engineering Department,
Faculty of Engineering and Technology,
Imam Khomeini International University,
Qazvin, Iran 34149-16818
e-mail: a.fazli@eng.ikiu.ac.ir

Behrooz Arezoo

CAD/CAM Research Center,
Mechanical Engineering Department,
Amirkabir University of Technology
(Tehran Polytechnic),
Hafez Street,
Tehran, Iran 15875-4413
e-mail: arezoo@aut.ac.ir

Mohammad H. Hasanniya

Materials Research and Engineering Department,
Supplying Automotive Parts Co. (SAPCO),
Tehran, Iran 13889-11498
e-mail: mhasanniya@sapco.com

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received February 23, 2013; final manuscript received January 16, 2014; published online March 26, 2014. Assoc. Editor: Gracious Ngaile.

J. Manuf. Sci. Eng 136(3), 031005 (Mar 26, 2014) (9 pages) Paper No: MANU-13-1074; doi: 10.1115/1.4026550 History: Received February 23, 2013; Revised January 16, 2014

A computer-aided design (CAD) system is developed for automatic process design and finite element (FE) modeling of axisymmetric deep drawn components. Using the theoretical and experimental rules, the system initially designs the process sequence of the component. The obtained process sequence is automatically modeled in abaqus software and the system tests whether failure occurs. The failure is supposed to happen when the fracture is predicted in FE simulation. If failure is predicted, the system changes the appropriate process parameters and carries out the simulation process again until all drawing stages are successful. The system returns the requested parameters for die design such as part geometries in middle stages, drawing forces, blank-holder forces, die, and punch profiles radii. The system is successfully tested for some components found in industry and handbooks.

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Figures

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Fig. 1

The flowchart of automatic process sequence design and finite element simulation of the component

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Fig. 2

Final geometry of a cylindrical component

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Fig. 3

Initial designed process sequence for the cylindrical component

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Fig. 4

FE simulation results and comparison of the strain distribution of the cylindrical component with statistical, M-K, and DFC predicted FLD for Initial designed process sequence. (a) 1st drawing stage (successful) and (b) 2nd drawing stage (failed).

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Fig. 5

Modified geometry of the second drawing stage

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Fig. 6

FE simulation results and comparison of the strain distribution of the cylindrical component with statistical, M-K and DFC predicted FLD for successful drawing stage. (a) 2nd drawing stage and (b) 3rd drawing stage.

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Fig. 7

(a) Experimental setup used for verification of designed process sequence. (b) Drawn cups in 1st and 2nd drawing stages.

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Fig. 8

Process sequence of flanged shell having two diameter-industrial practice [8]

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Fig. 9

Process sequence of flanged shell having two diameter; system output

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Fig. 10

Deformed shape for each drawing stage of the flanged two diameter component

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Fig. 11

Comparison of the strain distribution of the flanged two diameter component with statistical, M-K and DFC predicted FLD. (a) 1st drawing stage, (b) 2nd drawing stage, (c) 3rd drawing stage, and (d) 4th drawing stage.

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Fig. 12

Process sequence of a tapered concave shell; industrial practice [36]

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Fig. 13

Process sequence of a tapered concave shell; system output

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Fig. 14

Deformed shape for each drawing stage of a tapered concave shell

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Fig. 15

Comparison of the strain distribution of a tapered concave shell with statistical, M-K and DFC predicted FLD (a) 1st drawing stage, (b) 2nd drawing stage, (c) 3rd drawing stage, (d) 4th drawing stage, (e) 5th drawing stage, (f) 6th drawing stage, and (g) 7th drawing stage

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