An analysis of process and modelling parameters in sheet metal formability

The most important step for manufacturing of the sheet metal parts by means of stamping technology is to determine the optimum process conditions and to construct stamping dies which provide the production of such sheet metal parts. Therefore, the determination of the die process and design prior to the production of the dies, are very significant two stages that directly affect the manufacturing cost. Developing computer and engineering technologies contribute significantly to make the simulation of these stages with computers and also to the reduction of the costs. Finite Elements Method is one of the primary analytical approaches that are used for the simulation of production period for the time being. The aim of this study is to develop an effective method for the process design of the industrial sheet metal part by using FE method systematically. Therefore, it is necessary to know the level of effect of simulation parameter and assumptions in an engineering approach to computational results. Primarily, some basic information was given about the method and engineering approach considered to be used in the study. Then, in relation to the chosen stamping parameters, U-channel model has been used for examining the effects upon the results of the springback deformations that occur during stamping and thereafter. In this part of the study, the variabilities that originate from the mode of application method and the parameters that are needed for describing the physical process have been separately examined. The proposed engineering approach has been applied in the process and tooling designs of the chosen the industrial sheet metal part. The objective of this section is to determine the blank holder force?s effect that affects stamping process and drawbeads penetration quantity?s variability?s effect upon stamping and springback results and also determine the most suitable simulation parameters. Predicted parameter variabilities have been examined by doing an orthogonal design table. The calculated response surface functions have been used in order to determine the most appropriate parameters in process design. Determined process parameters and calculated results have been found satisfactory.