Morten Rikard Jensen

Applying the finite-element method for determination of tool wear in conventional deep-drawing

Abstract The prediction of tool wear in conventional deep-drawing is accomplished using the finite-element method. The distribution of tool wear on the draw-die profile is obtained and compared to industrial observations. This is achieved by proposing a semi-empirical wear model in which the tool wear is a function of both the normal pressure and the relative velocity between the sheet and the tooling. Furthermore, a parameter study has been carried out to see the effect on the tool wear when changing selected parameters, for example the blank thickness and the strain hardening.

Analysis of the hydromechanical deep drawing of cylindrical cups

The hydromechanical deep drawing process of aluminum cups and mild steel cups is analyzed experimentally and numerically. The effects of the process parameters on the final product quality are discussed. A working zone with a suitable maximum chamber pressure is obtained from the experimental results. The explicit finite element method is used with Hills transversely anisotropic material model for the numerical analysis. The numerical results are compared with those obtained in the experiments, process defects of local thinning are predicted and the thickness variations are discussed

Effect of anisotropy and prebulging on hydromechanical deep drawing of mild steel cups

Abstract The hydromechanical deep drawing processes of mild steel cups have been investigated experimentally and numerically. Experiments were carried out with the fixed gap method (with spacers) and the conventional method (without spacers) under different prebulging pressures. The shape variations and the thickness distributions of the workpieces were measured and discussed. The effects of anisotropy and prebulging pressure on the final product quality are discussed. The processes were analyzed by the explicit finite element code DYNA3D with the Barlat–Lian’s three-parameter material model. The numerical results are compared with those obtained in the experiments.

Numerical model for the oil pressure distribution in the hydromechanical deep drawing process

Abstract This paper presents an attempt to simulate the hydromechanical deep drawing process using the finite element method (FEM). The basic idea is to compute the counter pressure and the fluid film pressure by solving a finite difference approximation of Reynold’s equation. The concept is implemented as a contact algorithm in Exhale2D, an explicit finite element code for two-dimensional analyses. The numerical results illustrate a rather good agreement with experimental data.

Optimization of the draw-die design in conventional deep-drawing in order to minimise tool wear

Abstract An important problem in the production of drawn parts is tool wear, especially at the draw-die. If tool wear can be reduced this can increase the tool lifetime and make a more continuous production flow, due to a reduction in the number of break-downs when the tools have to be re-polished. This paper presents an attempt to reduce tool wear using the finite-element method and a general optimization technique to re-design the geometry of the draw-die profile of a deep-drawing with respect to minimizing the tool wear.

Aspects of Finite Element Simulation of Axi-Symmetric Hydromechanical Deep Drawing

A new approach for the Finite Element modelling of the hydromechanical deep drawing process is evaluated. In the model a Finite Difference approximation of Reynolds equation is solved for the flui ...