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Determination of Process Parameters for Stamping and Sheet Hydroforming of Sheet Metal Parts Using Finite Element Method

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Determination of Process Parameters for Stamping and Sheet Hydroforming of Sheet Metal Parts Using Finite Element Method DETERMINATION OF PROCESS PARAMETERS FOR STAMPING AND SHEET HYDROFORMING OF SHEET METAL PARTS USING FINITE ELEMENT METHOD DISSERTATION Presented in Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the Graduate School of The Ohio State University By Hariharasudhan Palaniswamy, M.S. * * * * * The Ohio State University 2007 Dissertation Committee: Approved by Professor. Taylan Altan, Adviser __________________________ Professor. Gary L. Kinzel Adviser Professor. Henry R. Busby Graduate program in Mechanical Engineering Professor. Jerald R. Brevick Copyright by Hariharasudhan Palaniswamy 2007 ABSTRACT Increase in the complexity of the parts and emphasis on the low formability and expensive lightweight materials require the use of multipoint cushion systems in modern presses and optimal blank shapes. Thus, better control of metal flow can be achieved for increasing the drawability and reducing the scrap rate and manufacturing cost in sheet metal forming. The blank holder force (BHF) / cushion pin force /cylinder force required to program the multipoint cushion system for forming a part is difficult and costly to estimate by trial and error FE simulation and die tryouts as there more than one variable to change. Hence, multipoint cushion system available in a modern press is hardly used in practice. Estimation of BHF to program the multipoint cushion system could be best done through structured FE simulations in process design stage so that its advantages can be incorporated in process design and carried forward to die tryout and production to realize its potential. Successful application of FE simulations in stamping process design depends on the accuracy of the input parameters. Conventionally, properties of sheet materials obtained from tensile test are used in FE simulation. This data is insufficient for the analysis because a) maximum strain obtained in uniaxial tensile test is small compared to strains encountered in stamping operations b) the stress state in tensile test is uniaxial while in regular stamping it is biaxial. Therefore, there is a need for biaxial test to accurately determine the material properties (flow stress and anisotropy constants) over larger strain range for forming FE simulations. In this study, the issue of appropriate test method to determine material properties for process simulation, the optimal blank shape determination, and the estimation of optimum force to program multipoint cushion system were addressed. Elliptical bulge test was developed to use along with circular bulge test to estimate flow stress and anisotropy of sheet materials over a large strain range, nearly twice that of tensile test for use in process simulation. The developed test was applied to estimate properties of DP600, AKDQ, BH210 steel and A5182-O aluminum alloy. Deep drawing simulations ii conducted using the material properties from the developed bulge test better correlated with experiments, compared to FE predictions using tensile test data. This result indicated that material properties obtained from bulge test are more appropriate for process simulation compared to tensile test. Numerical optimization technique coupled with FE analysis of the forming process was developed to predict optimum forces required to program the multipoint cushion system. Four possible modes for application of BHF in multiple-point cushion systems were considered, namely a) BHF constant in space/location and time/stroke, b) BHF variable in time/stroke and constant in space/location, c) BHF variable in space/location and constant in time/stroke and d) BHF variable in space/location and time/stroke. The optimum BHF was predicted by (a) minimizing the risk of failure by tearing (thinning) in the formed part and (b) avoiding wrinkling. The developed technique was applied to predict the BHF to form a) an automotive part (liftgate-inner) from A6111-T4 aluminum alloy and BH210 steel by stamping process, b) IFU-Hishida part from aluminum alloy A5182-O and BH210 steel by stamping process, c) 90 mm diameter roundcup from ST14 sheet material by sheet hydroforming process with punch (SHF-P) and d) a rectangular part from DP600 sheet material by sheet hydroforming with punch (SHF-D). Material properties obtained from biaxial tests, developed as part of this study were used in the FE simulation. Experimental results showed that the FEM based optimization methodology is able to predict the optimum BHF required to program multipoint cushion system for forming the parts without failure and significantly reduce trial and error effort in the investigated stamping and sheet hydroforming operations. BHF variable in space/location significantly improved the formability/drawbility compared to conventional method of BHF constant in space/location for the investigated parts in stamping and sheet hydroforming. In addition, element shape function based backtracking methodology was developed in this study to predict the optimal blank shape using FE simulation of forming process. The developed methodology “BLANKOPT” was successfully applied to predict optimum blank shape for an industrial part to eliminate post forming operation and reduce scrap, thereby reducing manufacturing cost. iii Dedicated to my family, and Lingappa Gounder, A.M. Saravana Gounder, V.K.Appachi Gounder and A.S. Shakthivadivel iv ACKNOWLEDGMENTS I wish to thank my adviser Prof. Taylan Altan for giving me the opportunity to do my graduate research at Engineering Research Center for Net Shape Manufacturing (ERC/NSM) and for his intellectual support of this work. His advice always encouraged me to give my best effort to my research. I would like to thank Prof. Gary L. Kinzel, Prof. Henry R. Busby and Prof. Jerald R. Brevick for accepting to be my dissertation committee members. I would like to thank Dr. M.Y. Demeri, Dr. C.T.Wang, and John Lowery of USCAR flexible binder project for sponsoring the research on programming multipoint cushion systems and providing helpful suggestions. I am grateful to Prof. H. Hoffmann, Institute for Metal Forming and Casting (Utg), Technical University, Munich, Germany, and Dr. B.Griesbach, AUDI AG, Ingolstadt, Germany, for providing invaluable opportunity for me to do an internship at AUDI AG, Germany. Also, I would like to thank Prof. E. Tekkaya, Institute of Forming Technology for Light Weight Construction, IUL, University of Dortmund, Germany, Dipl.- Ing. K. Schnupp of Schnupp Hydraulik, Bogen, Germany for providing press time and facility to do experiments in sheet hydroforming. I extend my sincere thanks to my colleagues at ERC/NSM, for their discussion and assistance. Special thanks are due to Dr. Gracious Ngaile, Dr. Hyunjoong Cho, Dr. v Yingyot Aue-u-lan, Dr. Ibrahim Al-Zkeri, Mr. Manas Shirgaokar, Mr. Ajay Yadav, Mr. Hyunok Kim, Dipl.-Ing. Meinhard Braedel, Dipl.-Ing, Ingo Faass, Dipl.-Ing. Micheal Mirtsch, Dr. Paolo Bortot, Mr. Giovanni Spampinato, Dipl.-Ing. Joerg Witulski, Mr. Arunkumar Thandapani, and Ms.Vandana Vavilikolane. Finally, my special thanks are extended to my parents, my brother and my relatives for their continuous support and encouragement during my PhD study at The Ohio State University, without their support, my graduate studies would not have been possible. vi VITA October 11, 1977……………………….Born - Erode, India 1998……………………………………...B.E., Mechanical Engineering, National Institute of Technology, (formerly, Regional Engineering College), Tiruchirappali, India. 1998-2000……………………………….Engineer, Sheet metal Tool Design TATA Motors Ltd, Pune, India. 2000-2007……………………………….Graduate Research Associate, Engineering Research Center for Net Shape Manufacturing (ERC/NSM). The Ohio State University, Columbus, Ohio 2006-2007………………………………Guest Researcher, AUDI AG, Ingolstadt, Germany PUBLICATIONS Peer reviewed journals 1. H.Palaniswamy, G.Ngaile, and T.Altan, 2004, “Optimization of blank dimensions to reduce springback in Flexforming process”, Journal of Material Processing Technology, Vol 146, pp.28-34 2. H.Palaniswamy, G.Ngaile and T.Altan, 2004, “Finite element simulation of magnesium alloy sheet forming at elevated temperatures”, Journal of Material Processing Technology, Vol 146, pp.52-60 3. S.Chandrasekaran, H.Palaniswamy, N.Jain, G.Ngaile and T.Altan, 2005, “Evaluation of stamping lubricants at various temperature levels using the ironing test”, International journal of machine tools and manufacture, Vol 45, pp.379-388 vii 4. H.Palaniswamy, M.Braedel, A.Thandapani, and T.Altan, 2006, “Optimal programming of multipoint cushion system for sheet metal forming”, Annals of CIRP, Vol 1, pp. 215-220 5. M.Braedel, H.Palaniswamy, H.Hoffmann, B.Griesbach, and T. Altan, 2007, “Investigation of die tryout using programmable multipoint cushion system for stamping large automotive body panels”, Manuscript prepared for submission to CIRP 2008 6. I.Fass, H.Palaniswamy, H.Hoffmann, B.Griesbach, and T. Altan, 2007, “ Effect of spacers on material flow for process control in automotive stamping”, Manuscript prepared for submission to CIRP 2008 7. H. Palaniswamy, A.Yadav, M.Braedel, M.Ujevic, T. Altan, 2007, “Process optimization and analysis for cost effective application of sheet hydroforming technology”, Manuscript prepared for review. 8. H. Palaniswamy, J. Witulski, V.Vavilikolane, M.Trompeter, E.Tekkaya, T. Altan, 2007, “Programming of multipoint cushion systems in sheet hydroforming technology”, Manuscript prepared for review. Non peer reviewed journals and Conferences 1. H.Palaniswamy, A.Thandapani, S.Kulukuru, and T.Altan, 2004,
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