Die vorliegende Arbeit hat die Untersuchung des Einlaufverhaltens beim Tiefziehen von Papier und Karton zum Ziel. Genauer wird das Materialversagen, welches durch Risse der Ziehteilzarge definiert ist, während der Umformung untersucht und quantifiziert. Das auftretende Verhalten des Materialversagens wird anhand einer gezielten Analyse der Systemdaten rekonstruiert und nachvollzogen. Dabei erweist sich die Reibarbeit, welche beim Transport des Ziehteiles durch die Ziehbüchse verrichtet werden muss, als signifikante Kenngröße zur Beschreibung des Materialversagens. Basierend auf dieser Ersatzkenngröße wird ein Modellentwurf zur Erkennung von fehlerhaften Ziehteilen durch Analyse der Systemdaten entwickelt. Zudem werden Versuchsreihen zur Ermittlung der Spezifikation der beim Umformen von Papier und Karton relevanten Materialeigenschaften durchgeführt, welche Anhaltspunkte bei Beschreibung der Versagensursachen geben. Weiterhin erfolgt die Untersuchung der auf den Ziehprozess einflussnehmenden Eigenschaften der Materialfeuchte und -temperatur. Des Weiteren wird ein Modell zur Quantifizierung von Ziehteileigenschaften entwickelt, anhand dessen qualitätsmindernde Eigenschaften reproduzierbar beschrieben werden können. Der Scherpunkt liegt dabei in der Untergliederung von maßgeblichen Eigenschaften in Formhaltigkeit und Faltenbild. / This thesis aims the investigation of the infeed behaviour of card board material during board pressing process. In addition, the material failure, which is defined as the breaking of the architrave of a pressing, will be examined and quantified in detail. The occurrence of material failure is reconstructed and simulated by using analysis system data. The work of friction, which must be executed during the transport of pressing through the implement, is a significant characteristic to describe that process. Based on that specification, an abstract model to detect defectives by monitoring the system data, is developed. Another focus of investigation is the process of an experimental series, developing the specification of the beard material, which is used as foundation to describe the causation of the material breakdown. Furthermore, a model of quantifying pressing qualities is developed focusing subdivision in dimensional accuracy and the quality of the crinkles.

Different contact surface parameters and operating characteristics are observed during the deep drawing process. It is not possible to find a formulation that can be used for all lubrication regimes. Therefore, several friction models have been developed in order to overcome this problem. In this study, a math program is developed which combines Wilson&rsquo / s and Khonsari&rsquo / s friction models in a new model in order to increase accuracy and efficiency in friction calculations. By comparing the results of both friction models, the film thickness ratio of 0.035 is introduced for 0.15 &mu / m standard deviation of surface summits. Below the ratio of 0.035, Khonsari&rsquo / s model gives more accurate results since asperity friction is dominant and the model is based on asperity contact. Above the ratio of 0.035, Wilson&rsquo / s model gives more accurate results since hydrodynamic friction is dominant and the model is based on lubricant flow. In this study, a finite element program is used to simulate 50 mm cylindrical and 50.5x50.5 mm square shallow drawing processes which are performed in single stage. The final cup depths are selected as 18 mm and 23 mm for square and cylindrical cup drawing respectively. The FEM model and the program codes developed are verified by the previous studies in literature. After verification, the simulation results of the cylindrical and square cup drawing are input to a math program which calculates local friction coefficients using the combined friction model. Finally, the combined friction model and the results are further discussed.

Abstract Today sheet metal forming is used to make a variety of mass production because it has a high production rate. One of the biggest concerns in sheet metal forming is wear of the tool in form of galling. Galling in sheet metal forming is characterised by an increased tool surface roughness, unstable friction in the forming process and undesirable scratches on the final products. Several ways of ranking materials resistance to galling exist today but only ASM G98 is standardised. Nevertheless, some different methods developed for ranking tool materials’ tendency to galling have also been developed. The aim of this thesis is to develop and improve the Uddeholm Tooling Tribo Test rig located at Uddeholm Tooling AB. The rig, which is a variation of cylinder-on-cylinder test equipment, was improved with a new tool holder, a utilization of the real sheet material counter face and a new data acquisition system and software. The galling was detected using scratches on the sheet, metallographic analysis of the material adhered on the tool specimen, monitoring of coefficient of friction and the standard deviation of the coefficient of friction. The obtained results show difficulties with ranking of tool materials in terms of galling resistance under non-lubricated conditions. The tool steels tested were SVERKER21 and UNIMAX. AISI304-10, DC04 and DOCOL1000DP sheets were used. Additionally a low friction coating of BalinitC on SVERKER21 was also included. All specimens of the tool steels showed signs of galling on every run, only the low friction coating showed a transition in behaviour of friction coefficient corresponding to galling initiation. The standard deviation of the coefficient of friction increased at low loads. A decrease of the test loads led to stability loss of the system detected by an increase in the standard deviation of the coefficient of friction. This might happen because the Kistler platform is originally designed for larger loads. Although, the test rig does not work properly in its present state, the concept looks promising.

In sheet metal forming operations the life length of the production equipment islargely dependent on the wear of the tools that are in direct contact with the sheet.One form of adhesive wear where some sheet material gets transferred to the tool, alsoknown as galling, is the most common cause of tool failure. The transferred materialsticks firmly to the tool and will scratch subsequent sheets and increase friction, renderingthem anywhere from aesthetically unsightly to completely ripped apart. Withcareful combination of several parameters the tools production life can be significantlyextended. The surface preparation of the tools has a large influence on the tool life, thesurface has to be smooth and yet not without texture. It was shown in strip reductiontesting that the orientation as well as the depth of the surface texture left by polishinginfluenced the tool life and that a texture perpendicular to the sliding direction was toprefer. The geometry of the forming tool is also a parameter to take into account as itinfluences the tool life not only by changing the contact pressure but also in itself. Ina sliding against flat sheet test rig a lower contact pressure increased the sliding distanceto galling. When two different geometries were compared at the same contactpressure it was found that there was a difference in tool life. As to the tool itself thematerial it’s made of influences the wear rate and tool life. Different tool steels wasinvestigated in sliding wear against metal sheets; Vancron 40 performed better thanVanadis 6 and S290PM performed better than a AISI M2 grade steel.

iv Sheet metal forming technologies are challenged especially by the improvements in the automotive industry in the last decades. To fulfill the customer expectations, safety requirements and market competitions, new production technologies have been implemented. This study focuses on the assessment of conventional and new sheet metal forming technologies by performing a systematic analysis. A geometry spectrum consisting of six different circular, elliptic, quad cross-sections are selected for the assessment of conventional deep drawing, hydro-mechanical deep drawing and high-pressure sheet metal forming. Within each cross-section, three different equivalent drawing ratios are used as a variant. More than 200 numerical experiments are performed to predict the forming limits of three competing processes. St14 stainless steel is used as the material throughout the assessment study. The deformation behavior is described by an elasto-plastic material model and all numerical simulations are carried out by using dynamic-explicit commercial The process validation is done by interpreting the strain results of numerical experiment. Therefore, the reliability of predictions in the assessment study highly depends on the quality of simulations. The precision of numerical experiments are verified by comparing to NUMISHEET benchmarks, analytical formulation, and experiments to increase the assets of the assessment study. The analyses revealed that depending on the workpiece geometry and dimensional properties certain processes are more preferable for obtaining satisfactory products. The process limits for each process are established based on the analyzed crosssections of the spectrum. This data is expected to be useful for predicting the formability limits and for selecting the appropriate production process according to a given workpiece geometry.Dynamic-explicit FEM, Deep drawing, Hydroforming, Forming limits, Process evaluation

Thesis (Ph. D.)--Ohio State University, 2008. / Title from first page of PDF file. Includes bibliographical references (p. 169-178).

Die vorliegende Arbeit hat die Entwicklung und Umsetzung einer graphischen Benutzeroberfläche zur Erprobung von Wechselwirkungen zwischen verschiedenen Prozessparametern beim Tiefziehen von faserbasierten Materialien, wie Papier und Karton, zum Ziel. Nach einer Recherche zum Prozess des Tiefziehens und seiner Modellierung folgt das Erarbeiten von Grundsätzen bei der Erstellung und Gestaltung von graphischen Benutzerschnittstellen. Insbesondere steht dabei die Art der Eingabe von numerischen Parametern und die Visualisierung von Informationen im Vordergrund. Bei der Erstellung des Layouts des Graphical User Interface (GUI) werden die aus der Recherche gewonnenen Erkenntnisse genutzt. Dazu werden alle Anforderungen, die an die Benutzerschnittstelle gestellt werden können, zusammengetragen. Bekannte Annahmen zur Modellierung des Tiefziehprozesses werden aus Vorarbeiten verwendet. So wird innerhalb des Programmcodes der GUI der Stempelkraftverlauf beim Tiefziehen mit seinen charakteristischen Kennwerten erzeugt. Diese Kennwerte werden in einer ausgewählten Darstellungsform auf der Oberfläche für den Nutzer anschaulich präsentiert. Ein Vergleich mit den charakteristischen Werten einer Referenz in der Darstellung erlaubt eine Aussage über die Qualität des zu produzierenden Ziehformteiles. Nach der Implementierung der GUI werden abschließend Potentiale für weiterführende Arbeiten offengelegt. / The aim of this thesis is the development and implementation of a GUI for testing interactions between different process parameters in the deep drawing of fibre based materials such as paper and cardboard. After an investigation of the process of deep drawing and its modelling, the elaboration of principles of the creation and the design of the GUI follows. The main focus concentrates in particular on the type of input of numerical parameters and the visualization of information. Based on the findings from the research, the layout of the GUI is created. To this end, all requirements that can be posed on the user interface are combined. Known assumptions for the modelling of the deep drawing process are used from reliminary work. Thus, within the program code of the interface, the punch force profile during deep drawing is generated with its characteristic values. These characteristic values are displayed in a selected presentation form on the user's surface. A comparison with the characteristic values of a reference in the presentation allows a statement about the quality of the drawing part to be produced. After the implementation of the GUI the potentials for further development are finally disclosed.

O processo de microestampagem permite a fabricação de peças ou microcomponentes, podendo ser aplicado a diversas áreas da engenharia. Logo, este trabalho tem por objetivo desenvolver um micromotor de passo e avaliar os efeitos da miniaturização de seus componentes. A simulação computacional foi utilizada neste trabalho de forma a avaliar os defeitos surgidos com a miniaturização, através do software de elementos finitos DYNAFORM com “solver” LS-DYNA. O material empregado na carcaça foi o aço de baixo carbono ABNT 1010 e o aço inoxidável ABNT 304, e para o núcleo magnético do micromotor, composto pelo rotor e estator, utilizou-se o aço elétrico ABNT 35F 420M. A simulação computacional, além de identificar os problemas oriundos da miniaturização dos componentes, também foi utilizada para otimizar as ferramentas de microestampagem, demonstrando desta forma ser uma grande aliada para o desenvolvimento do processo. O processo de corte convencional em matriz não foi aplicado no corte do rotor e do estator, pois produziu defeitos como empenamento e rebarbas. Ao invés disso, empregou-se o processo de corte por eletroerosão a fio, que produziu peças planas e superfícies lisas. / The process of micro deep drawing is a micro-technology which allows the fabrication of microcomponents and can be applied to various fields of engineering. This study aims to develop the components of a micromotor step using this technology and to evaluate the effects of the microfabrication of the motor frame, rotor and stator. A computer simulation was carried out in order to evaluate miniaturization of the components trough the finite element software DYNAFORM with “Solver” LS-DYNA. The material used in the motor housing was low carbon steel ABNT 1010 and stainless steel ABNT 304. However, in magnetic core, comprising the rotor and stator, the electric steel ABNT 35F 420M was employed. Micro deep drawing tools were developed based on the results obtained through simulation is a great ally to create microcomponents. The cutting process in the matrix was not employed to cut de rotor and the stator, because it produced defects such as warping and butts along the surface. Instead, wire cutting spark erosion was used and resulted in hat part and surfaces.

The desire to reduce weight in automotive products is driven by a need to improve efficiency. As such, to allow further weight reduction, higher performance aluminium alloys are in demand for sheet metal body structures. Due to their high strength to weight ratio 7xxx alloys are seen as an ideal candidate for this, however their use to date has been limited by poor formability. Previous work indicated that by moving to high temperatures (>350°C) or by using a soft temper (W), good formability could be achieved but the samples required further heat treatment post-forming. This work explored the warm forming temperature range to improve formability whilst developing the required properties during processing. The performance of a 7xxx candidate alloy, 7021, has been assessed in stretching and drawing operations, both at room temperature and over the elevated temperature range of 150-250°C. The microstructure and other properties of the alloy were investigated in W, T4 and T6 tempers, before and after testing, through a range of techniques, including DSC, DMTA, SEM, EBSD and TEM.In the T4 temper, UTS and proof stress increased with temperature up to 190°C, due to dynamic precipitation. Increasing temperature only provided a modest increase in strain to failure for both the T4 and T6 temper. Cup height was not significantly improved in the warm forming temperature range during Erichsen cup testing. By deep drawing at 250°C it was possible to fully draw a cup (with an LDR of 2.2) in both the T4 and T6 temper of 7021, with both tempers having comparable post-forming hardness. This indicates that at 250°C the starting condition has no impact on drawability. Although full drawability is achieved at 250°C the final product would require further heat treatment if it were to replace 6016. However, by deep drawing 7021-T4 at 190°C, a fully formed cup was produced with a hardness between that of the T4 and T6 temper. The microstructure of the formed cup showed no grain boundary precipitation and a fine distribution of the strengthening phase η', suggesting there is a dynamic effect on the precipitation during deep drawing at this temperature. In conclusion, the work has shown that warm forming does not significantly improve stretching behaviour of 7021, but by using warm forming temperatures deep drawing is improved.

Made available in DSpace on 2014-06-11T19:28:33Z (GMT). No. of bitstreams: 0 Previous issue date: 2009-05-04Bitstream added on 2014-06-13T20:58:27Z : No. of bitstreams: 1 guidi_es_me_guara.pdf: 1324172 bytes, checksum: 59b78521e70777f3852a654d667e11b1 (MD5) / Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / Dentre os processos de conformação mecânica de metais por deformação plástica, a estampagem possui grande importância por possibilitar a obtenção de produtos de diversos formatos, semi-acabados ou acabados e com boas propriedades mecânicas. A simulação computacional utilizando o método dos elementos finitos apresentou um grande desenvolvimento na última década, hoje é uma importante ferramenta de análise de projetos. Neste trabalho é apresentada a elaboração de um arquivo paramétrico, em linguagem APDL, de simulação do processo de estampagem de copos cilíndricos para o programa comercial ANSYS® 7.0. Este arquivo é construído de maneira automática por um programa criado no software de programação DELPHI 7.0. O paramétrico irá auxiliar o projetista na análise das variáveis do processo de estampagem e no desenvolvimento de ferramental, permitindo realizar um estudo dessas variáveis de maneira isolada ou com vários fatores simultâneos. Para a validação do arquivo paramétrico foram realizados ensaios que foram confrontados com os resultados obtidos nas simulações. / Among the processes of forming metals by plastic deformation, the stamping possesses great importance for facilitating the obtaining the products of several formats, near net-shape or net-shape and with good mechanical properties. The computacional simulation using the finite elements method presented a great development in the last decade, today it is an important tool of analysis the projects. In this work the elaboration of a parametric file, in language APDL, of simulation of the stamping process of cylindrical cups for the commercial program ANSYS® 7.0. This file is built in an automatic way by a program making in the programming software DELPHI 7.0. The parametric will help the designer in the analysis of the stamping process variables and development of tools, allowing accomplishing a study of these variables alone or with several factors simultaneously. For validation of the file parametric was accomplished experimentals that were confronted with the results obtained in the simulations.