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research-article

Modeling and analysis of the process energy for cylindrical drawing

[+] Author and Article Information
Lei Li

School of Mechanical Engineering, Hefei University of Technology, Hefei 230009, P. R. China
hfut_lilei@hotmail.com

Haihong Huang

School of Mechanical Engineering, Hefei University of Technology, Hefei 230009, P. R. China
huanghaihong@hfut.edu.cn

Fu Zhao

School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907-2088, USA; Environmental and Ecological Engineering, Purdue University, West Lafayette, IN 47907-2088, USA
fzhao@purdue.edu

Xiang Zou

School of Mechanical Engineering, Hefei University of Technology, Hefei 230009, P. R. China
xiangzouhfut@163.com

Gamini Mendis

Environmental and Ecological Engineering, Purdue University, West Lafayette, IN 47907-2088, USA
gmendis@purdue.edu

Xiaona Luan

School of Mechanical Engineering, Shandong University, Jinan 250061, P. R. China; Key Laboratory of High-efficiency and Clean Mechanical Manufacture (Ministry of Education), Shandong University, Jinan 250061, P. R. China
xiaona0412@126.com

Zhifeng Liu

School of Mechanical Engineering, Hefei University of Technology, Hefei 230009, P. R. China
zhfliuhfut@126.com

John Sutherland

Environmental and Ecological Engineering, Purdue University, West Lafayette, IN 47907-2088, USA
jwsuther@purdue.edu

1Corresponding author.

ASME doi:10.1115/1.4041924 History: Received February 27, 2018; Revised November 04, 2018

Abstract

As energy efficiency increases in importance, researchers have identified manufacturing processes as opportunities where energy consumption can be reduced. Drawing is one widely employed, energy intensive manufacturing process which could benefit by analysis of energy consumption during operation. To optimize the energy consumption of the drawing process, this paper developed an explicit model to quantify the process energy for the cylindrical drawing process by analyzing the dynamic punch force during the process. In this analysis, the evolution of the stress and strain were analyzed in the drawn part by considering all the structure parameters of the drawn part. The stress and strain analyses were integrated into an overall process energy model, and the behavior of the model was classified into three categories, based on their physical mechanisms, i.e., deformation energy, bending energy, and friction energy. The model was validated using numerical experiments designed by the Taguchi method where two different kinds of materials were tested over eighteen runs. The results from the numerical experiments were compared with those from the model, and show that the maximum variation of the process energy predicted by this model is less than 10% for a given part. Sensitivity analysis was performed on the model to understand the contributions of the process parameters on the process energy to guide process optimization for lower energy consumption. The established model can assist in the rapid design of drawn parts with lower embodied energy.

Copyright (c) 2018 by ASME
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