This master’s thesis deals with suggestion of production of sheet metal cover in Limid Mohelno s.r.o. Piece serves as cover of regulation device of rail vehicles with visual function and it’s manufactured from corrosion-resistant steel ČSN 17 240 with thickness 1 mm. Esthetical impression is ensured by grinded surface K240. The master’s thesis includes literary studies and problems of chosen technologies, technological calculations and choice of machines including tools. As the best manufacturing technology was chosen punching on TruPunch 1000 and bending on press brake SafanDarley E-Brake E-100. Technical and economical evaluation was made based on selected technology and compared with another manufacturing options.

Aus der Einleitung: "Um Kosten in der Produktentwicklung weiter zu minimieren und gleichzeitig die Qualität der zu fertigenden Produkte zu gewährleisten, nehmen virtuelle Methoden in der Produktentwicklung einen immer größeren Stellenwert ein (Stelzer & Eigner, 2009). An die Maßhaltigkeit von umgeformten Blechteilen werden ständig höhere Anforderungen gestellt. Die Ursachen für Maßabweichungen an gefertigten Blechteilen resultieren maßgeblich aus den Berechnungsmodellen, die das System Werkzeug-Blechteil-Umformmaschine bisher in der Virtuellen Produktentwicklung noch nicht vollständig und exakt abbilden können. Mehrere Zyklen händischer Änderungen an den Umformwerkzeugen sind heute noch die Regel. Dieser Prozess wird bei der Blechumformung als Einarbeitungsphase bezeichnet und wird von Spezialisten des Werkzeugbaus unter Nutzung von unscharfem Erfahrungswissen durchgeführt. Der Zyklus der manuellen Einarbeitungsphase im Bereich des Werkzeugbaus steht den wirtschaftlichen Forderungen zum schnelleren Serienanlauf und zur Kostensenkung entgegen. Hier kann die Verkürzung des Einarbeitungsprozesses dienlich sein."

Bisherige Bemühungen zur Reduzierung der Rückfederung von Blechbauteilen begrenzten sich hauptsächlich auf die Gestaltung der letzten Formgebungsstufe. In der vorliegenden Arbeit wird ein innovativer Ansatz zur Erhöhung der Maßhaltigkeit durch die Modifikation der Vorziehstufe untersucht. Dabei wird auf Grundlage eines beispielhaften Industriebauteils ein Demonstrator mit einer offenen und einer geschlossenen Kontur entwickelt. Durch die Abbildung der Herstellungsmethode in der Simulation (FEM) lässt sich die Rückfederung beurteilen. Durch die Charakterisierung des Werkstoffverhaltens wird die Qualität der Simulation gesteigert, da die Materialkennwerte (Fließkurve & Grenzformänderungskurve) für die Simulation genauer spezifiziert werden können. Es erfolgt die Variation der Vorziehstufe hinsichtlich geometrischer (Radius & Grad der Vorziehstufe) und prozesstechnischer Parameter (Niederhalterkraft & Schließabstand), sodass nach der Auswertung der Rückfederungsergebnisse Gestaltunghinweise erarbeitet werden. Die Validierung der Simulationsergebnisse wird vorgenommen, indem die Bauteile real hergestellt werden. Dadurch ist es möglich, die Rückfederungen der Simulation und der realen Herstellungsmethode zu vergleichen und die Gestaltungshinweise zu bewerten. / Approaches to reduce springback of sheet metal parts are mainly focused on the last forming stage. This study deals with modifications made on the pre-drawing stage so that an increased dimensional accuracy results. A demonstrator with an open and a closed contour is developed based on an exemplary industrial part. The assessment of springback is conducted by incorporating the manufacturing method into simulation (FEM). To increase the quality of the simulation the characterization of materials is set and hence more information about material properties (flow curve and forming limit curve) is specified. Variations of geometric (radius & proportion of pre-drawing stage) and process parameters (blankholder force & closing distance) are made which purpose the development of design guidelines after evaluation. The simulation results are validated by producing real sheet metal parts. The design guidelines will be feasible/can be assessed if the comparison of the springback results converges between simulation and reality.

The car industry produces many of their car parts by using sheet metal forming, where one of the most time-consuming phases is the development and manufacturing of new forming tools. As of today, when a new tool is to be evaluated in terms of usability, a forming simulation is conducted to predict possible failures before manufacturing. The assumption is then that the tools are rigid, and the only deformable part is the sheet metal itself. This is however not the case, since the tools also deform during the forming process. A previous research, which is the basis of this thesis, included a model with only elastic tools and showed results of high accuracy in comparison to using a rigid setup. However, this simulation is not optimal to implement for a daily based usage, since it requires high computational power and has a long simulation time.  The aim and scope for this thesis is to evaluate how a sheet metal forming simulation with elastic tool consideration can be reduced in terms of computational cost, by using the software LS-DYNA. A small deviation of the forming result is acceptable and the aim is to run the simulation with a 50-75 % reduction of time on fewer cores than the approximate 14 hours and 800 CPUs that the simulation requires today. The first step was to alter the geometry of the tools and evaluate the impact on the deformations of the blank. The elastic solid parts that only has small deformations are deleted and replaced by rigid surfaces, making the model partly elastic. Later, different decomposition methods are studied to determine what kind that makes the simulation run faster. At last, a scaling analysis is conducted to determine the range of computational power that is to be used to run the simulations as efficient as possible, and what part of the simulation that is affecting the simulation time the most. The correlation of major strain deviation between a fully elastic model and a partly elastic model showed results of high accuracy, as well as comparison with production measurements of a formed blank. The computational time is reduced by over 90 % when using approximately 65 % of the initial computational power. If the simulations are run with even less number of cores, 10 % of the initial number of CPUs, the simulation time is reduced by over 70 %. The conclusion of this work is that it is possible to run a partly elastic sheet metal forming simulation much more efficient than using a fully elastic model, without reliability problems of the forming results. This by reducing the number of elements, evaluate the decomposition method and by conducting a scaling analysis to evaluate the efficiency of computational power. / Bilindustrin producerar många av sina bildelar genom att tillämpa plåtformning, där en av de mest tidskrävande faserna är utveckling och tillverkning av nya formningsverktyg. Idag, när ett nytt verktyg ska utvärderas med avseende på användbarhet, genomförs en formningssimulering för att förutsäga eventuella fel innan tillverkning. Antagandet är då att verktygen är stela och den enda deformerbara delen är själva plåten. Det är dock inte så, eftersom verktygen också deformeras under formningsprocessen. Tidigare forskning, som ligger till grund för detta examensarbete, inkluderade en modell med endast elastiska verktyg och visade resultat med hög noggrannhet i jämförelse med att använda stela verktyg. Simuleringen med elastiska verktyg är emellertid inte optimal att implementera för daglig användning, eftersom den kräver hög beräkningskraft och har en lång simuleringstid. Syftet och omfattningen av detta examensarbete är att utvärdera hur en plåtformningssimulering med elastiska verktyg kan minskas med avseende på beräkningskostnaden, genom att använda programvaran LS-DYNA. En liten avvikelse från formningsresultatet är acceptabelt, och målet är att köra simuleringen med en 50-75 % minskning av tiden på färre kärnor än ungefär 14 timmar och 800 processorer som simuleringen kräver idag. Det första steget är att ändra verktygets geometri och utvärdera inverkan på deformationerna av plåten. De elastiska solida verktygsdelarna som endast har små deformationer raderas och ersätts av stela ytor, vilket gör modellen delvis elastisk. Senare studeras olika dekompositionsmetoder för att avgöra vilka som gör simuleringen snabbare. Till sist utförs en skalningsanalys för att bestämma antalet processorer som ska användas för att köra simuleringen så effektivt som möjligt. Korrelationen av huvudtöjningarna mellan en helt elastisk modell och en delvis elastisk modell visade resultat av hög noggrannhet, såväl som jämförelse med produktionsmätningar av en format plåt. Beräkningstiden minskar med över 90 % när man använder ungefär 65 % av den ursprungliga beräkningskraften. Om simuleringarna körs med färre antal kärnor, cirka 10 % av ursprungligt antal CPUer, minskar simuleringstiden med 70 %.  Slutsatsen av detta arbete är att det är möjligt att köra en delvis elastisk plåtformningssimulering mycket effektivare än att använda en helt elastisk modell, utan att de resulterar i pålitlighetsproblem. Detta genom att minska antalet element, utvärdera dekompositionsmetoden och genom att genomföra en skalningsanalys för att utvärdera effektiviteten av beräkningskraften. / Reduced Lead Time through Advanced Die Structure Analysis - Swedish innovation agency Vinnova

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Aluminium alloys have the possibility to be infinitely recycled. By only generating 5% of the emissions compared to primary aluminium, great CO2 savings can be made. One of the issues in manufacturing components entirely from post-consumer scrap is the presence of trace elements and impurities. Such elements can be Fe, Cu, Cr, P and Pb. In sheet metal manufacturing, these elements can also react with process agents such as Ti, B, Na and Sr and affect the recrystallization behavior and in turn mechanical properties.In this work, a derivative of the 3003 alloy made entirely from post-consumer scrap has been analysed. The alloy achieved insufficient formability due to lack of recrystallization and grain growth. With the use of scanning electron microscopy (SEM) equipped with energy dispersive spectroscopy (EDS) and electron backscatter diffraction (EBSD) together with focused ion beam (FIB) lamella preparation, the microstructure was characterized.The characterization shows both larger particles of α-Al15Si2M4 (M=Mn,Fe,Cr) from solidification and dispersoids from heat treatment, pinning the grain boundary movement together with Q-AlCuMgSi. With the use of high throughput computational thermodynamics, Thermo-Calc was used to effectively screen compositions lowering the amount of α-Al15Si2M4 and removing the Q-AlCuMgSi phase. The new alloy was cast using directional solidification at different cooling rates to study the particle morphology, which in turn plays a role in the particle break up and distribution during cold working as the interparticle spacing affects the grain growth.Varying cooling rates was seen to affect morphology and distribution. Hot compression was utilized to examine the particle redistribution before cold work. It was however shown that hot compression was not sufficient in redistributing the particles as would be the case in rolling.

Numerische Prozessanalysen werden heute standardmäßig zur virtuellen Prozessabsicherung der Herstellung umgeformter Blechformteile eingesetzt. Die dabei notwendige hohe Prognosegüte kann nur mit einer hinreichend präzisen Materialmodellierung realisiert werden. Ein wesentlicher Aspekt ist dabei die Modellierung des Fließverhaltens und der Werkstoffanisotropie. Zur Charakterisierung des Werkstoffverhaltens existieren zahlreiche Versuchs- und Auswertestrategien; diese werden aufgrund des hohen Versuchs- und Rechenaufwands in der industriellen Anwendung jedoch nur vereinzelt eingesetzt. Im Rahmen dieser Arbeit wird eine neuentwickelte halbanalytische Methode zur Charakterisierung von Fließortkurven sowie der Folgefließortkurven vorgestellt. Dazu wurde eine Spannungsanalyse auf Messdaten einer digitalen Bildkorrelation sowie ein Schnittlinienansatz zur Berechnung innerer Kräfte entwickelt. Durch Bilanzierung dieser inneren Schnittkräfte mit gemessenen äußeren Prüfkräften werden Parameter eines gewählten Materialmodells in einer inversen Analyse identifiziert. Die Methode zur Parameteridentifikation wurde zunächst an synthetischen und anschließend an realen Experimenten untersucht. Es wurde eine sequentielle Identifikationsstrategie aufgestellt, die an den Blechwerkstoffen DX54, DP600 sowie AA5182 untersucht wurde. Abschließend wurde die Methode mithilfe von Validierungsversuchen hinsichtlich der identifizierten Materialantworten überprüft.:Inhaltsverzeichnis I Symbolverzeichnis IV Abkürzungen und Begriffe VIII 1 Einleitung 1 2 Stand der Technik 3 2.1 Grundlagen zur Umformung von Blechwerkstoffen 3 2.1.1 Umformprozesse zur Herstellung von Blechformteilen 3 2.1.2 Anforderungen bei der Herstellung von Blechbauteilen 4 2.2 Numerische Prozessauslegung von Blechumformoperationen 5 2.2.1 Anwendung der FEM als Hilfsmittel in der Prozessauslegung 5 2.2.2 Kritische Punkte der numerischen Prozessauslegung 7 2.3 Werkstoffverhalten und Materialmodellierung 8 2.3.1 Kenngrößen zur Beschreibung großer Deformation 8 2.3.2 Grundlagen zur Beschreibung elastoplastischen Materialverhaltens 9 2.3.3 Beschreibung der Verfestigungsregel in Materialmodellen 11 2.3.4 Modellierung anisotroper Fließortkurven 12 2.3.5 Modellierung der Fließortkurvenentwicklung 18 2.3.6 Zusammenfassende Hinweise zu den Fließkriterien 25 2.4 Kennwertermittlung und Werkstoffcharakterisierung 26 2.4.1 Experimentelle Methoden und analytische Verfahren zur Fließortkurvenermittlung 26 2.4.2 Erweiterte Messtechnik zur Identifikation von Fließortkurven 33 2.4.3 Inverse Strategien zur Identifikation von Fließortkurven 36 2.5 Zusammenfassung zum Stand der Technik 43 3 Zielsetzung und Vorgehensweise 45 3.1 Zielsetzung 45 3.2 Vorgehensweise 45 4 Experimentelle Versuchsdurchführung 47 4.1 Versuchsaufbau und Messtechnik 47 4.2 Prüfverfahren zur Werkstoffprüfung 48 4.2.1 Zugversuch 49 4.2.2 Kerbzugversuch 49 4.2.3 Scherzugversuch 49 4.2.4 Biaxialer Zugversuch 50 4.3 Wahl der Versuchswerkstoffe 51 4.3.1 Kaltgewalzter Tiefziehstahl DX54 51 4.3.2 Kaltgewalzter Dualphasenstahl DP600 52 4.3.3 Aluminiumknetlegierung AA5182 52 4.4 Messergebnisse aus den Werkstoffprüfungen 53 4.5 Zusammenfassung zur Versuchsdurchführung 55 5 Entwicklung einer halbanalytischen Methode zur Parameteridentifikation 56 5.1 Spannungsanalyse 56 5.1.1 Spannungsrichtung 57 5.1.2 Spannungszuwachs 58 5.1.3 Elastische Kompensation 59 5.2 Schnittkraftermittlung 60 5.3 Inverse Analyse 62 5.4 Zusammenfassende Darstellung der Entwicklung 64 6 Validierung der Methode an virtuellen Experimenten 67 6.1 Virtuelle Versuche 67 6.2 Validierung der Spannungsanalyse 68 6.2.1 Vorgehensweise zur Prüfung der Spannungsanalyse 69 6.2.2 Ergebnisse der Überprüfung der Spannungsanalyse 70 6.3 Validierung der Schnittkraftermittlung 76 6.4 Sensitivität der Materialantwort gegenüber den Materialparametern 80 6.4.1 Einfluss variierender Fließkurvenapproximationen 80 6.4.2 Einfluss variierender Fließortkurven 82 6.5 Diskussion zur Wahl geeigneter Schnittlinien 88 6.6 Fehlerbetrachtung 89 / Numerical process analysis is widely used today for the virtual process validation of the production of formed sheet metal parts. In this context, sufficiently precise material modeling is essential, especially for the flow behavior and the material anisotropy. Numerous test and evaluation strategies are known for the material characterization. However, these strategies are only used occasionally in industrial applications due to high experimental and computational costs. In the context of this work, a newly developed semi-analytical method for the characterization of yield locus curves and subsequent yield locus curves is presented. For this purpose, a stress analysis based on digital image correlation data and a cutting-line approach for internal forces computation was developed. By balancing these internal cutting forces with measured external test forces, parameters of a material model are identified in an inverse analysis. The method for parameter identification was first examined on synthetic and subsequently on real experiments. A sequential identification strategy was set up and examined on the sheet metal materials DX54, DP600 and AA5182. Finally, the method was checked using validation tests with regard to the identified material responses.:Inhaltsverzeichnis I Symbolverzeichnis IV Abkürzungen und Begriffe VIII 1 Einleitung 1 2 Stand der Technik 3 2.1 Grundlagen zur Umformung von Blechwerkstoffen 3 2.1.1 Umformprozesse zur Herstellung von Blechformteilen 3 2.1.2 Anforderungen bei der Herstellung von Blechbauteilen 4 2.2 Numerische Prozessauslegung von Blechumformoperationen 5 2.2.1 Anwendung der FEM als Hilfsmittel in der Prozessauslegung 5 2.2.2 Kritische Punkte der numerischen Prozessauslegung 7 2.3 Werkstoffverhalten und Materialmodellierung 8 2.3.1 Kenngrößen zur Beschreibung großer Deformation 8 2.3.2 Grundlagen zur Beschreibung elastoplastischen Materialverhaltens 9 2.3.3 Beschreibung der Verfestigungsregel in Materialmodellen 11 2.3.4 Modellierung anisotroper Fließortkurven 12 2.3.5 Modellierung der Fließortkurvenentwicklung 18 2.3.6 Zusammenfassende Hinweise zu den Fließkriterien 25 2.4 Kennwertermittlung und Werkstoffcharakterisierung 26 2.4.1 Experimentelle Methoden und analytische Verfahren zur Fließortkurvenermittlung 26 2.4.2 Erweiterte Messtechnik zur Identifikation von Fließortkurven 33 2.4.3 Inverse Strategien zur Identifikation von Fließortkurven 36 2.5 Zusammenfassung zum Stand der Technik 43 3 Zielsetzung und Vorgehensweise 45 3.1 Zielsetzung 45 3.2 Vorgehensweise 45 4 Experimentelle Versuchsdurchführung 47 4.1 Versuchsaufbau und Messtechnik 47 4.2 Prüfverfahren zur Werkstoffprüfung 48 4.2.1 Zugversuch 49 4.2.2 Kerbzugversuch 49 4.2.3 Scherzugversuch 49 4.2.4 Biaxialer Zugversuch 50 4.3 Wahl der Versuchswerkstoffe 51 4.3.1 Kaltgewalzter Tiefziehstahl DX54 51 4.3.2 Kaltgewalzter Dualphasenstahl DP600 52 4.3.3 Aluminiumknetlegierung AA5182 52 4.4 Messergebnisse aus den Werkstoffprüfungen 53 4.5 Zusammenfassung zur Versuchsdurchführung 55 5 Entwicklung einer halbanalytischen Methode zur Parameteridentifikation 56 5.1 Spannungsanalyse 56 5.1.1 Spannungsrichtung 57 5.1.2 Spannungszuwachs 58 5.1.3 Elastische Kompensation 59 5.2 Schnittkraftermittlung 60 5.3 Inverse Analyse 62 5.4 Zusammenfassende Darstellung der Entwicklung 64 6 Validierung der Methode an virtuellen Experimenten 67 6.1 Virtuelle Versuche 67 6.2 Validierung der Spannungsanalyse 68 6.2.1 Vorgehensweise zur Prüfung der Spannungsanalyse 69 6.2.2 Ergebnisse der Überprüfung der Spannungsanalyse 70 6.3 Validierung der Schnittkraftermittlung 76 6.4 Sensitivität der Materialantwort gegenüber den Materialparametern 80 6.4.1 Einfluss variierender Fließkurvenapproximationen 80 6.4.2 Einfluss variierender Fließortkurven 82 6.5 Diskussion zur Wahl geeigneter Schnittlinien 88 6.6 Fehlerbetrachtung 89

L’objectif de ce sujet de thèse est de prédire l’apparition des instabilités plastiques (striction diffuse et striction localisée) dans les matériaux métalliques. Ces matériaux sont décrits par des modèles de comportement élasto-plastique couplés à l’endommagement. L'approche de Lemaitre, reliant l'endommagement à la déformation plastique équivalente et au taux de restitution de la densité d'énergie élastique, est adoptée. Parmi les différents critères et indicateurs qui sont considérés pour la prédiction des instabilités matériau, la théorie de bifurcation et les critères de type force maximum sont tout particulièrement analysés et comparés. Un objectif important de cette étude consiste à déterminer les mécanismes déstabilisants clés associés à cette modélisation du comportement, ainsi que l’impact des différents aspects physiques et des paramètres matériau sur l’apparition de la striction. Les développements résultants sont appliqués à une sélection représentative de matériaux métalliques afin prédire leurs limites de formabilités. Cette approche combinant des lois de comportement et critères de striction peut être utilisée comme outil théorique et numérique d’aide à la conception de nouveaux matériaux à ductilité améliorée / The aim of the present work is to predict the occurrence of plastic instabilities (diffuse and localized necking) in thin sheet metals. The prediction of these plastic instabilities is undertaken using an elastic–plastic model coupled with ductile damage, which is then combined with various plastic instability criteria theory. The bifurcation-based criteria and the maximum force criterion used in this work are formulated within a general three-dimensional modeling framework, and then applied for the particular case of plane-stress conditions for sheet metals. Some theoretical relationships or links between the different investigated necking criteria are established, which allows a hierarchical classification in terms of their conservative character in predicting critical necking strains. The resulting numerical tool is implemented into the finite element code ABAQUS/Standard to predict forming limit diagrams, in both situations of a fully three-dimensional formulation and a plane-stress framework. This approach, that combines constitutive equations to necking criteria, serves as a useful tool in the design of new materials with improved ductility

Made available in DSpace on 2016-12-08T15:56:19Z (GMT). No. of bitstreams: 1 Ricardo Kirchhof Unfer.pdf: 99775 bytes, checksum: 27709fdea77151b3e21cfdaf92146d6e (MD5) Previous issue date: 2015-08-28 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / The new contributions of present thesis are an alternative experimental waviness method and a new theoretical model for evaluation of limit strains of sheet metal forming in the automotive industry, employing the analysis of roughness and waviness parameters evolution with the equivalent plastic strain and a new ductile rupture criterion as function of stress triaxiality. For validation of proposed experimental waviness method and rupture criterion, specimens of IF steel sheet of thickness 0.72mm, 0.82mm and 0.85mm were tested under tensile test and Nakazima sheet forming test with Marciniak flat punch. The specimens were deformed in incremental steps in different strain path such as: balanced biaxial stretching, plane strain, uniaxial tension and pure shear. Present proposed method consider that roughness and waviness parameters are important surface quality index and useful as indicator of onset of visible local necking and should be monitored in sheet metal forming. Thus, a Waviness Limit Curve, WLC, is proposed to be plotted in Map of Principal Limit Strains (MDLC) of sheet metal as an alternative to the forming limit strain curve, FLC. Various parameters of roughness and waviness such as arithmetic average roughness (Ra), maximum peak-valley roughness (Rt), arithmetic average waviness (Wa), total heigth peak-valley waviness (Wt), maximum peak height waviness (Pp) and maximum valley depth waviness (Pv) were measured during the uniaxial and biaxial testing. Tensile test of IF steel specimens at 0º, 45º and 90º to the rolling direction, RD, and Nakazima type of IF steel specimens at 0º RD only, in which a mesh of 2.5mm circles were printed, were employed. During the uniaxial and biaxial testing, the following plastic deformations were calculated in each straining step from the printed circles in the sheet surface: major true strain (1) and minor true strain (2). Parameters of roughness and waviness versus equivalent plastic strain curves were plotted to obtain a phenomenological equation of 4th and 3rd degree polynomials, using the Hill 1979 yield stress criterion. Furthermore, the growth rate of parameters Wa and Wt with equivalent plastic strain were calculated. From the growth rate, it was possible to conclude that the sheet 12 thickness imperfections, measured by Wa and Wt, evolve during material deformation, being possible to predict with accuracy the influence of equivalent plastic strain in the onset of local necking. From the experimental analysis, it was concluded that the maximum peak-valley waviness parameter (Wt) was the best option to chacaracterized the beginning of local necking in IF steel sheet forming. Thus, from the analysis of waviness growth rate parameters, Wa and Wt, during plastic strains, it was possible to propose a criterion of local necking inception. This allowed to obtain and plot an experimental Waviness Limit Curve (WLC) in the map MDLC: the beginning of local necking was established when the normalized parameter Wt* (=Wt/Wto) attained a critical value Wt*= 2.5, but with distinct values of equivalent strains. A second mathematical model was proposed for local necking criterion to obtain the FLC of IF steel sheets, employing stress triaxiality analysis and the Hill 1979 yield stress criterion. 2nd degree polynomials were obtained from plotted and adjusted phenomenological curves in graphs of equivalent strain at rupture versus stress triaxiality, considering the different plastic strain path in the formability testing. The IF steel specimens showed ductile rupture, according to scanning electronic microscope examinations, which showed that rupture occurred due to formation, growth and coalescence of large quantity of pores in many specimens of balanced biaxial (BB) and plane strain (DP). Also, mixed rupture of ductile type due to shear mechanisms in certain regions of tensile test (TS) and Nakazima uniaxial tension (UTN) specimens were shown. / As propostas de ineditismo da presente tese foram mostrar um método experimental alternativo de rugosidades e um modelo teórico de ruptura novo para se avaliar as deformações limites de conformação de chapas metálicas da indústria automobilística, empregando-se uma análise da evolução dos parâmetros de ondulação da rugosidade com a deformação plástica equivalente e um critério de ruptura dúctil em função da triaxialidade das tensões. Para validação do método experimental de rugosidades e do critério de ruptura propostos, utilizou-se corpos de prova de chapas de aço IF de 0,72mm, 0,82mm e 0,85mm de espessura, que foram submetidas aos ensaios de tração simples e ensaio de estampagem tipo Nakazima com punção plano de Marciniak. As amostras foram sujeitas a deformação incremental em diferentes trajetórias de deformação, tais como: estiramento biaxial balanceado, deformação plana, estiramento uniaxial e cisalhamento puro. O presente método proposto considera que parâmetros de rugosidade e ondulação são índices importantes de qualidade da superfície e servem como indicador preciso do início da estricção local visível e devem ser monitorados na conformação de chapas metálicas. Portanto, propõe-se traçar uma Curva Limite de Ondulação da Rugosidade, CLOR, no Mapa das Deformações Principais Limite de Conformação (MDLC) das chapas metálicas como alternativa da curva limite de conformação, CLC. Vários parâmetros do perfil de rugosidade e da ondulação da rugosidade tais como a rugosidade média aritmética (Ra), altura máxima pico-vale (Rt), ondulação média aritmética (Wa), a altura máxima da ondulação pico-vale (Wt), altura máxima de pico da ondulação (Pp) e profundidade máxima de vale (Pv) foram medidos durante os ensaios uniaxiais e biaxiais. Foram utilizados corpos de prova de aço IF em tração simples a 0º, 45º e 90º da direção de laminação, DL, e corpos de prova tipo ensaio Nakazima de aço IF somente a 0º DL nos quais foram impressos uma malha de círculos de 2,5 mm de diâmetro. Durante os ensaios uniaxiais e 10 biaxiais, as seguintes deformações plásticas foram calculadas em cada etapa a partir da malha de circulos impressos na superficie da chapa: a deformação verdadeira longitudinal maior (1) e a deformação verdadeira transversal menor (2). Curvas dos parâmetros de rugosidade e ondulações versus deformação plástica equivalente, empregando-se o critério de escoamento plástico de Hill (1979), foram traçados para se obter equações fenomenológicas do tipo polinomial de 4° e 3° graus. Além disso, foram calculadas as taxas de crescimento dos parâmetros Wa e Wt com a deformação plástica equivalente. A partir das curvas de taxas crescimento, foi possível concluir que as imperfeições na espessura da chapa, medidas por meio de Wa e Wt, evoluem durante a deformação do material, sendo possível prever com precisão a influência da deformação plástica equivalente no início do surgimento da estricção local. Concluiu-se então que o parâmetro da altura máxima total pico-vale das ondulações (Wt) é a melhor opção para caracterizar o início da estricção local em chapas de aço IF. Portanto, a partir da análise das taxas de crescimento dos parâmetros de ondulação, Wa e Wt, durante as deformações plásticas, foi possível propor um critério para o surgimento da estricção local. Isto permitiu obter e traçar a curva experimental de Limite de Ondulação da Rugosidade, (CLOR), no Mapa MDLC: o início da estricção local foi quando o parâmetro normalizado Wt* (=Wt/Wto) atingiu o valor crítico Wt*=2,5, mas com valores distintos da deformação equivalente. Um segundo modelo matemático foi proposto como critério de estricção local para obtenção da CLC de chapas de aço IF, empregando-se análise da triaxialidade de tensões e o critério de escoamento plástico de Hill (1979). Foram obtidos polinômios de 2º grau por meio de curvas fenomenológicas ajustadas e traçadas nos gráficos de triaxialidade de tensões versus deformação equivalente de ruptura, considerando-se as diferentes trajetórias da deformação plástica dos ensaios de conformabilidade. As amostras de chapa de aço IF mostraram ruptura dúctil conforme exame no microscópio eletrônico de varredura, o qual mostra que a fratura ocorreu devido a formação, crescimento e coalescência de uma grande quantidade de espaços vazios ou poros na maioria dos corpos de prova tipo Biaxial Balanceado (BB) e Deformação Plana (DP). Também, as amostras apresentaram fraturas mistas do tipo dúcteis e com mecanismos de cisalhamento em determinadas regiões das amostras fraturadas em Tração Simples (TS) e Tração Uniaxial de Nakazima (UTN).

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / In order to get a better part quality in sheet metal forming, the rate of the material flow into the die cavity must be efficiently controlled. This control is made by a restraining force supplied either by the blankholder, the drawbeads or both. When the restraining force required is too high, the use of drawbeads is necessary, although excessive deformations may be produced. Some others disadvantages, such as difficulties of adjustment during die try-outs in order to determine the actual Drawbead Restraining Force (DBRF), may also be emphasized. To solve these problems and to reduce the number of die try-outs, which are very time consuming, accurate enough drawbeads concepts are necessary. Aiming to understand the influence of the most important parameters on the DBRF and to establish a pre-estimate DBRF theory, in this study a methodology has been developed using similitude. The data bases were achieved by Finite Element (FE) simulations done with an explicit code. Two different materials were used: A-K Steel and 2036-T4 Aluminum. The results have been compared with experimental databases of Nine(1978, 1982) and with the analytical model of Stoughton(1988). The average of absolute error with respect to experimental data bases was about 6 % and, for those cases studied, the maximum discrepancy was found to be less than 11%. For analytical ones, the average of absolute error was about 5 % and, for the cases studied, the maximum error was about 7%. Predictions made with this approach have a very good precision when compared with analytical and experimental results. For this reason, it was used as a contribution for STAMPACK®, an explicit finit element code used to simulate forming process. / Para se obter peças com a melhor qualidade possível em um processo de estampagem de chapas metálicas, a taxa de fluxo de material para dentro da matriz deve ser eficientemente controlada. Este controle é feito por uma força de retenção (FR) originada no prensachapas, nos freios de estampagem ou em ambos. Quando a FR requerida é muito alta, o uso dos freios se torna ainda mais necessário, embora excessivas deformações possam ocorrer na peça estampada por causa do contato com os freios. Outros tipos de efeitos indesejáveis decorrentes do uso deste tipo de dispositivos ainda podem ocorrer, tais como dificuldades para se determinar o valor adequado da FR, o que pode consumir muito tempo. Para se resolver estes problemas e reduzir o número das tentativas de ajustes, são necessários conceitos mais precisos sobre os freios de estampagem. Com a finalidade de se avaliar a influência dos parâmetros mais importantes na FR e de se estabelecer uma teoria para se fazer a predição da FR, desenvolveu-se neste estudo uma metodologia híbrida, empregando-se a teoria da similitude com bases de dados gerados através de simulações numéricas pelo Método dos Elementos Finitos (MEF). Os resultados foram comparados com os experimentos de Nine (1978, 1982) e com o modelo analítico de Stoughton (1988). A média dos desvios absolutos com respeito aos dados experimentais foi de 6% e, para os casos estudados, a discrepância máxima foi sempre menor ou igual a 11%. Em relação ao modelo analítico, a média dos desvios absolutos foi de 5% e, para os casos estudados, o desvio máximo nunca foi superior a 7%. Predições feitas com esta abordagem tiveram, portanto, uma boa precisão, quando comparadas com o modelo analítico e com os dados experimentais. Por este motivo, esta teoria foi aceita como contribuição para o programa STAMPACK®, um código de solução explícita utilizado na simulação de processos de estampagem de chapas metálicas. / Doutor em Engenharia Mecânica