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Research Papers

Comparison of Offset and Wiping Z-Die Designs for Precision Z-Bent Part Fabrication

[+] Author and Article Information
Sutasn Thipprakmas

Department of Tool and Materials Engineering,
King Mongkut's University of
Technology Thonburi,
126 Bangmod, Thungkhru,
Bangkok 10140, Thailand
e-mail: sutasn.thi@kmutt.ac.th

Pakkawat Komolruji

Department of Tool and Materials Engineering,
King Mongkut's University of
Technology Thonburi,
126 Bangmod, Thungkhru,
Bangkok 10140, Thailand

Wiriyakorn Phanitwong

Department of Tool and
Materials Engineering,
King Mongkut's University of
Technology Thonburi,
126 Bangmod, Thungkhru,
Bangkok 10140, Thailand;
Department of Industrial Engineering,
Rajamangala University of
Technology Rattanakosin,
96 Mu 3 Phutthamonthon Sai 5 Road,
Salaya, Phutthamonthon,
Nakhon Pathom 73170, Thailand
e-mail: wiriyakorn.wp@gmail.com

1Corresponding author.

Manuscript received March 22, 2017; final manuscript received December 11, 2017; published online January 3, 2018. Assoc. Editor: Christopher Tyler.

J. Manuf. Sci. Eng 140(2), 021015 (Jan 03, 2018) (9 pages) Paper No: MANU-17-1155; doi: 10.1115/1.4038727 History: Received March 22, 2017; Revised December 11, 2017

In recent years, the requirements for high dimensional precision on Z-bent shaped parts have become increasingly stringent. To attain these requirements, the suitable selection of the Z-die bending type has to be considered much more strictly. In this research, two types of Z-bending processes, offset Z-die bending and wiping Z-die bending, were investigated using the finite element method (FEM) to identify the spring-back characteristics and dimensions of Z-bent shaped parts. In the case of offset Z-die bending, the spring-back characteristics on both bend angles were similar. In contrast, in the case of wiping Z-bending, the spring-back characteristics on both bend angles were different. In addition, the dimensions of the Z-bent shaped parts were investigated. It was found, in the case of wiping Z-bending, that web thinning was generated and the outer bend radius was out of tolerance. To validate the FEM simulation results, experiments were carried out. The FEM simulation results showed good agreement with the experimental results in terms of the bend angles and the overall geometry of the Z-bent shaped parts. To achieve precise Z-bent shaped parts, the suitable selection of Z-die bending type in the Z-die bending process is very important.

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References

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Figures

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Fig. 1

FEM simulation model of the offset Z-bending type: (a) initial stage and (b) bending stage

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Fig. 2

FEM simulation model of the wiping Z-bending type: (a) initial stage and (b) bending stage

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Fig. 3

Critical bent part dimensions: (a) offset Z-bending type and (b) wiping Z-bending type

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Fig. 4

The punch and die components for experiments: (a) offset Z-bending type and (b) wiping Z-bending type

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Fig. 5

Illustration of dimension measurements: (a) measured web thickness positions and (b) measured bend angles and bend radii

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Fig. 6

Comparison of the bend angles and web thicknesses between the FEM simulation and the experimental results: (a) offset Z-die bending type and (b) wiping Z-die bending type

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Fig. 7

Stress distribution analysis during bending phase in the case of offset Z-die bending type: (a) bending stroke 1.95 mm, (b) bending stroke 10.35 mm, and (c) bending stroke 10.43 mm

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Fig. 8

Stress distribution analysis during bending phase in the case of wiping Z-die bending type: (a) bending stroke 3.30 mm, (b) bending stroke 12.89 mm, (c) bending stroke 19.77 mm, and (d) bending stroke 20.00 mm

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Fig. 9

Predicted bend angles and spring back values after unloading phase in the case of offset Z-die bending type: (a) predicted bend angles and (b) predicted spring back values

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Fig. 10

Predicted bend angles and spring back values after unloading phase in the case of wiping Z-die bending type: (a) predicted bend angles and (b) predicted spring back values

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Fig. 11

Predicted web thickness after unloading phase: (a) offset Z-die bending type and (b) wiping Z-die bending type

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Fig. 12

Predicted bend radius after unloading phase: (a) offset Z-die bending type and (b) wiping Z-die bending type

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