This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Optimal Forming of Aluminum 2008-T4 Conical Cups Using Force Trajectory Control
Annotation ability available
Sector:
Language:
English
Abstract
In this paper we investigate the optimal forming of conical cups of AL 2008-T4 through the use of real-time process control. We consider a flat, frictional binder the force of which can be determined precisely through closed-loop control. Initially the force is held constant throughout the forming of the cup, and various levels of force are tested experimentally and with numerical simulation. Excellent agreement between experiment and simulation is observed. The effects of binder force on cup shape, thickness distribution, failure mode and cup failure height are investigated, and an “optimal” constant binder force is determined. For this optimal case, the corresponding punch force is recorded as a function of punch displacement and is used in subsequent closed-loop control experiments.
In addition to the constant force test, a trial variable binder force test was performed to extend the failure height beyond that obtained using the “optimal” constant force level. It was found that this method could indeed improve performance, and the cause of this improvement is examined through the use of the numerical model. Numerical simulation is then used to compute a “best” variable binder force history and the further improvement in cup failure height is obtained.
Although optimal forming trajectories were found under constant and variable binder force conditions, there is no guarantee that lubrication or sheet conditions will remain constant during an actual forming operation. Therefore, the process must be controlled in order to include such disturbances in the loop. Accordingly, a closed-loop tangential force controller is constructed and made to track the pre-determined force trajectory corresponding to the optimal conditions. Results show that optimal conditions can be maintained upon significant variation of initial binder force.
Recommended Content
| Technical Paper | Influence of Oxygen Storage Characteristics on Automobile Emissions |
| Technical Paper | Microkinetics Modeling of Catalytic Converters |
| Technical Paper | Measuring Reliability |
Authors
Topic
Citation
Jalkh, P., Cao, J., Hardt, D., and Boyce, M., "Optimal Forming of Aluminum 2008-T4 Conical Cups Using Force Trajectory Control," SAE Technical Paper 930286, 1993, https://doi.org/10.4271/930286.Also In
References
- Anand, L. Tong, W. Pisoni, A. Parks D.M. 1992
- Blumel, K. Frings, A. Hartmann G. 1992 “Shearing and Stamping Hot-Rolled Material” Autobody Stamping Applications and Analysis, SAE SP-897
- Fenn, R.C. 1989 “Closed-Loop Control of Sheet Metal Stability During Stamping” Massachusetts Institute of Technology, Dept. Mechanical Engineering
- Fenn, R. Hardt D.E. 1990 “Real-Time Sheet Forming Stability Control” Proc. International Deep Draw Research Group June Stockholm
- Fenn, R. Hardt D.E. 1992 “Real-Time Control of Sheet Stability During Forming” ASME Journal of Engineering for Industry
- Hibbitt, Karlsson and Sorensen, Inc. 1988 ABAQUS User's Manual and Theory Manual, version 4.9-1 HKS Providence, RI
- Hirose, Y. Hishida, Y. Furubayashi, T. Oshima, M. Ujihara S. 1990 “Part I: Techniques for Controlling Wrinkles by Controlling the Blank Holding Force” Proc. 4th Symposium of the Japanese Society for the Technology of Plasticity
- Hirose, Y. Hishida, Y. Furubayashi, T. Oshima, M. Ujihara S. 1990 “Part II: Application of BHF-Controlled Forming Techniques” Proc. 4th Symposium of the Japanese Society for the Technology of Plasticity
- Kergen, R. Jodogne P. 1992 “Computerized Control of the Blankholder Pressure on Deep Drawing Processes” Autobody Stamping Applications and Analysis, SAE SP-897
- Lee, C.Y. 1986 “Closed-Loop Control of Sheet Metal Stability During Forming” Massachusetts Institute of Technology, Dept. Mechanical Engineering
- Lee, C.Y. Hardt D.E. 1986 “Closed-Loop Control of Sheet Metal Stability During Stamping” 1986 North American Manufacturing Research Conference May 28-30
- Logan, R.W. 1985 “Sheet Metal Formability Simulation and Experiment” University of Michigan
- Ortiz, M. Leroy, Y. Needleman A. 1987 “A Finite Element Method for Localized Failure Analysis” Computer Methods in Applied Mechanics and Engineering 61
- Rebelo, N. Nagtegaal, J.C. Hibbitt H.D. 1990 “Finite Element Analysis of Sheet Forming Processes” Int. Jnl. for Numerical Methods in Engineering 30
- Sim, H.B. 1990 “Numerical Simulations of Stability Control in Sheet Metal Forming” Massachusetts Institute of Technology, Dept. Mechanical Engineering
- Sim, H.B. Boyce M.C. 1992 “Finite Element Analyses of Real-Time Stability Control in Sheet Forming Processes” ASME Journal of Engineering Materials and Technology 114