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Rao, B. V. S.
- Numerical Studies on the Effect of Various Parameters on Wrinkling in Deep Drawing of Cylindrical Cups
Abstract Views :267 |
PDF Views:1
Authors
Affiliations
1 Department of Mechanical Engg., CBIT, Gandipet, Hyderabad, IN
2 Department of Mechanical Engg., JNTU College of Engg., Hyderabad, IN
1 Department of Mechanical Engg., CBIT, Gandipet, Hyderabad, IN
2 Department of Mechanical Engg., JNTU College of Engg., Hyderabad, IN
Source
Manufacturing Technology Today, Vol 15, No 7 (2016), Pagination: 3-14Abstract
Deep drawing is the process of converting a blank into cup shaped articles like kitchen sinks, utensils, fountain pen caps etc. Wrinkles and fracture are the major defects in deep drawn products. Wrinkles occur at flange as well as the sidewalls of a deep drawn cup. The main reason for wrinkles is inadequate blank holding force. However excessive blank holding force results in fracture. The aim of this work is to arrive at optimum blank holding force in order to produce wrinkle free products. In this work numerical simulations are conducted by considering five different parameters namely punch radius, die radius, clearance, coefficient of friction and Punch diameter using finite element explicit solver LSDYNA. Modeling of the set up is done using hyper mesh. In this work simulations are carried out as per L-27 orthogonal array suggested by Taguchi. A combination of finite element method and Taguchi analysis is used to determine the influence of process parameters in deep drawing.Keywords
Deep Drawing, Blank Holding Force, Wrinkling, Taguchi Approach, LSDYNA.
- Determination of Blank Size for Non Axisymmetric and Non Standard Deep Drawn Cups
Abstract Views :176 |
PDF Views:5
Authors
Affiliations
1 Chaitanya Bharathi Institute of Technology (CBIT), Hyderabad, IN
2 Mahatma Gandhi Institute of Technology, Hyderabad, IN
3 J.N.T.U. College of Engineering, Hyderabad, IN
1 Chaitanya Bharathi Institute of Technology (CBIT), Hyderabad, IN
2 Mahatma Gandhi Institute of Technology, Hyderabad, IN
3 J.N.T.U. College of Engineering, Hyderabad, IN
Source
Manufacturing Technology Today, Vol 14, No 7 (2015), Pagination: 3-14Abstract
Deep Drawing is the process of converting a flat blank into cup shaped articles like automobile panels kitchen sinks, fountain pen caps and shell cases etc. During this process a punch forces the blank to take the shape of the die cavity. If the height of the drawn cup exceeds half its diameter then the process can be termed as deep drawing. One of the primary requirements in drawing operation is estimation of blank area or blank size. It is considered to be critical because even a small variation in estimation can lead to unnecessary wastage of material. If the blank area is underestimated it leads to partially drawn cup due to insufficient material. On the other hand if the blank area is over estimated it leads to wastage in material as the excess material has to be removed by performing trimming operation. Although estimation of blank diameter is done using mathematical formulae these are based on thumb rules which are in turn based on experience. Further for nonstandard and nonaxisymmetric cups there are hardly any readymade formulae available. Hence in this work an effort is made to estimate the blank size required to form nonstandard and nonaxisymmetric cups produced by deep drawing process, both analytically and by using solid works software.- Modernistic Method of Enhancing Productivity by Reusing of Slag as Flux in Submerged Arc Welding & Study of its Impact on Mechanical Properties
Abstract Views :184 |
PDF Views:3
Authors
Affiliations
1 University of North Carolina at Charlotte, US
2 Department of Mechanical Engineering, Chaitanya Bharathi Institute of Technology (CBIT), Gandipet, Hyderabad, Telangana, IN
1 University of North Carolina at Charlotte, US
2 Department of Mechanical Engineering, Chaitanya Bharathi Institute of Technology (CBIT), Gandipet, Hyderabad, Telangana, IN
Source
Manufacturing Technology Today, Vol 16, No 10 (2017), Pagination: 3-11Abstract
Submerged arc welding (SAW) is an industrial welding process in which the joint is obtained by heating the metal with an arc set between bare electrode and work piece. Intense heat produced during the process fuses the metal and filler metal. Flux is used as a shielding agent to protect the molten weld pool from atmospheric contamination. This flux gets converted into slag after solidification at the surface of welding metal. This slag is thrown away after performing welding. This leads to increase in the cost of process hence reuse of slag is a cost effective method. In this present work different flux and slag compositions are used to analyse the effect of slag & flux mixture on mechanical properties of submerged arc welded joint performed on mild steel plates. Further this work is an attempt to utilize the mixture of slag and flux and reduce the cost of SAW welding process. For the investigation, 6 different compositions of slag and flux are made by varying slag percentage in each sample starting from 0 % to 100 %. The different output parameters of interest are studied such as Penetration, Bead Width, Reinforcement, Microstructure, Tensile Strength and Hardness. The best slag composition which is inferred from the test results are found to be Composition No 2(20% Slag) & Composition No 3 (40% Slag).Keywords
Submerged Arc Welding, Flux, Slag, Reuse of Slag, Cost Effective Method.References
- Jatinger Garg; Amish Gupta; To Evaluate the Effect of Saw Parameters on Slag Content of Weld Metal, 'International Journal of Science and Technology' IJSN 123.45.
- Dalgobind Mahto; Anjani Kumar: Novel Method of Productivity Improvement and Waste Reduction Through Recycling of Submerged Arc Welding Slag, 'Jordan Journal of Mechanical and Industrial Engg'. vol. 4, Sep 2010 , ISSN 1995-6665.
- Sandeep Krishnan Kant; Mohit Bector; Anoop Verma: Reclamation of Slag as Flux Composition by the effect of welding parameters in Submerged Arc Welding.
- Kulwant Singh , Handip Singh ‘ Bead Geometry with Crushed Slag in Submerged Arc Welding’ Journal of Manufacturing Engg, June 2011 , vol. 6, no. 2, 120-125.
- Amit Gupta; Pawan Kumar Sapra; Naveen Singla; Gora Ram: Effect of Various Flux Compositions Mixed With Slag on Mech.Properties of Structural Steel Weld Using Submerged ARC Welding, 'Asian Review of Mechanical Engg' ISSN 2249 - 6289, vol. 2, no. 2, 2013, 27-31.
- Jaswinder Singh; Kulwant Singh; Jatinger Garg: Reuse of Slag as Flux in Submerged Arc Welding & its Effect on Chemical Composition, Bead Geometry & Microstructure of the Weld Metal, 'Int J of Surface Engg & Materials Technology', vol. 1, no. 1, July-Dec, 2011, ISSN:2249-7250
- Impact of Drawing Ratio and Shape on Thickness Distribution along the Walls of Deep Drawn Cups
Abstract Views :363 |
PDF Views:3
Authors
Affiliations
1 Department of Mechanical Engineering, CBIT, Hyderabad, IN
1 Department of Mechanical Engineering, CBIT, Hyderabad, IN
Source
Manufacturing Technology Today, Vol 17, No 6 (2018), Pagination: 3-10Abstract
Deep drawing is the process of converting a flat blank into cup shaped articles. In this process a punch forces the blank to take the shape of die cavity. Different shapes and sizes of products for automotive bodies, structural parts, utensils and beverage cans are manufactured by this process. Using bimetallic strip in preparing the various products by deep drawing has become the recent trend in manufacturing process. The main reason to carry out such a process is taking the advantages of different materials such as high strength, low density and corrosion resistibility, at the same time and in a single component. The cost of the component gets reduced too. In the deep drawn cups the thickness of the sheet metal varies throughout the walls of cup. This is undesirable as non uniform thickness leads to defects like cracks or failures. As thickness variation depends upon several parameters like limit drawing ratio, drawing force, sheet material, geometry of blank etc. it can be minimized by selecting optimum process parameters.
This work is related to deep drawing of cups which are made using bimetallic strip. The objective of this work is to study the variation in thickness along the side walls of deep drawn cups which are made using bimetallic material i.e. Cu-Al and also to determine the optimum drawing ratio for producing a cup of specific size. The study was carried out in Amba Bhavani tool crafts and Metal Forming lab of CBIT. In this work the variation in thickness along the walls of cup for three different shapes, i.e: circular, square, heart. were investigated. The studies reveal that the variation in thickness is different for different shaped cups and also the variation in sheet thickness is different when Copper and Aluminium are in turn made as inside surfaces of bimetallic cups.
Keywords
Bimetallic, Deep Drawing, Thickness Variation.References
- Tera, Melania and Biris, Cristina: Consideration On The Selection Of The materials for the Releasing Of Deep Drawing Bimetallic Parts, Metal 2008, 13-15.5.2008, Hradec and Moravici.
- Stefan, Kapinski: The Analysis of Forming Process For Bimetal materials, 'Transactions of Engineering Sciences', vol 14 , 1997.
- Tera, Melania; Bologa, Octavian; Breaz, Radu; Chera, Lonut; Tirnovean, Sorin: Study of Incremental Deep-Drawing Of Bimetallic Sheets, 'Proceedings In Manufacturing systems', vol. 7 , no. 4, 2012.
- Atrian, Amir; Dereshteh, Saniee F: Deep Drawing Process Of Steel/Bass Laminated Sheets, Composites Part B Engineering, Elsevier, November 2013.
- Kagzi, Shakil A; Gandhi, Anish H; Dave, Harshit K & Raval, Harit K: An Analytical Model For Bending And Springback Of Bimetallic Sheets, Mechanics of Advanced Materials and structures , vol. 23, no. 1, 2016
- Brabie, G; Costache, EM; Nanu, N; Chirita Vasile Alecsandri B: Prediction and Minimisation of Sheet Thickness Variation During Deep Drawing of Micro/Milli Parts, 'International Journal of Mechanical Sciences', vol. 68, 277-290, 2013.
- Peled, A; Rubin, MB; Tirosh, J: Analysis of Blank Thickening in Deep Drawing Processes Using the Tehory of a Cosserat Generalized Membrane, 'Journal of the Mechanics and Physics of Solids', vol. 52, 317-341, 2004.
- Tahir Altinbalik, et.al.,: Numerial and Experimental Study of Sheet Thickness Variation In Deep Drawing Process, 'International Journal of Modern Manufacturing Technologies', ISSN 2067-3604, vol. 4, no.2, 2012
- Magaret, SM et.al., Studies on Deep Drawing of Steel Cups for the Variation of Yield Strength and Drawing Ratio Using FEA, MIT International Journal of Mechanical Engineering, vol. 3, no. 1, Jan. 2013, 1-5, ISSN No. 2230-7680 MIT Publications.
- Prof. A C Sekhara Redy et.al., Experimental Study on Strain Variation and Thickness Distribution in Deep Drawing of Axisymmetric Components, 'International Journal of Engineering Research &Technlogy (IJERT)', ISSN: 2278-0181, vol. 2, no. 12, Dec-2013.
- Mrs. Ketaki N Joshi et. al., Optimization of Variation in Wall Thickness of a Deep Drawn Cup using Virtual Design of Experiments, IRACST – Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498, vol. 4, no. 5, October 2014.
- Swadesh Kumar Singh and Ravi Kumar, D: Numerical Prediction of Limiting Draw Ratio and Thickness Variation in Hydro-mechanical Deep Drawing, 'International Journal of Materials and Product Technology', vol. 21, no. ½ , 2004, 106-123.
- Younis, AD: The effect of drawing ratio in deep drawing process on thickness distribution along the cup, vol. 18, no. 4, Iraq academy of scientific journals (IASJ).
- Ozek, Cebeli and Muhammet Bal: The effect of die/punch radius and drawing ratio on the wall thickness in deep drawing dies, 'Journal of the faculty of engineering and architecture of Gazi university', 24.1, 2009, 33-41.
- Seah, KHW; Lee, KS: Parametric Studies In Deep Drawing, 'Journal Of Manufacturing Engineering (SME)', Published: 01/10/1987 Product ID: TP87PUB203
- Mathematical Modeling and Analysis of Hoop Stresses in Hydro-Forming Deep Drawing of n-Sided Polygonal AA1100, Galvanized Commercial Steel Cup
Abstract Views :165 |
PDF Views:0
Authors
G. Kishan
1,
B. V. S. Rao
2
Affiliations
1 UCETW, Kakatiya University, Warangal, Telangana, IN
2 CBIT, Osmania University, Hyderabad, Telangana, IN
1 UCETW, Kakatiya University, Warangal, Telangana, IN
2 CBIT, Osmania University, Hyderabad, Telangana, IN
Source
Manufacturing Technology Today, Vol 20, No 1-2 (2021), Pagination: 9-14Abstract
The main objective of this paper presents the analytical evaluation and mathematical modeling of hoop stresses of metallic cups of materials such as AA1100 and galvanized commercial steel in hydro forming deep drawing of n-sided polygonal cup. It is very important to find the magnitude of these stresses produced within the flange area. Two types of stresses will be established in the flange region. One of it is radial stress. It usually occurs radial outward from the side of the cup to the outer side of the blank material. Another is hoop stress. It can be generated in the flange. It is compressive in nature and perpendicular to the radial lines drawn to the side of the blank from the job axis. It is either parallel to the blank circumference or tangential to it. Inside of the blank material, these two stresses will be created by the use of punch forKeywords
Hydro-Forming Deep Drawing, Hoop Stress, n-Sided Polygonal Cup.References
- Abedrabbo, N., Zampaloni, M. A., & Pourboghrat F. (2005). Wrinkling control in aluminum sheet hydroforming. International Journal of mechanical Sciences, 47(3), 333-358. https://doi.org/10.1016/j.ijmecsci. 2005.02.003
- Lang, L., Danckert, J., & Nielsen, K. B. (2004). Investigation into hydrodynamic deep drawing assisted by radial pressure: Part I. Experimental observations of the forming process of aluminum alloy. Journal of Materials Processing Technology, 148(1), 119-131. https://doi.org/10.1016/j.jmatprotec.2004.01.053
- Lang, L., Danckert J., & Nielsen, K. B. (2005). Investigation into hydrodynamic deep drawing assisted by radial pressure: Part II. Numerical analysis of the drawing mechanism and the process parameters. Journal of Materials Processing Technology, 166(1), 150-161. https://doi.org/10.1016/j.jmatprotec.2004.08.015
- Thiruvarudchelvan, S., & Travis, F. W. (2003). Hydraulic-pressure enhanced cup-drawing processes - An appraisal. Journal of Materials Processing Technology, 140(1-3), 70-75. https://doi.org/10.1016/S0924-0136(03)00726-X
- Thiruvarudehelvan, S., & Lewis, W. (1999). A note on hydro-forming with constant fluid pressure. Journal of Materials Processing Technology, 88(1), 51-56. https://doi.org/10.1016/S0924-0136(98)00378-1
- Uadaykumar, R., Ravinder Reddy, P., & Sitaramaraju, A. V. (2017). Determination of Hoop Stresses in Hydro-forming Process. Materials today proceedings, 4(8), 9133-9140. https://doi.org/10.1016/j.matpr.2017.07.269
- Yossifon, S., & Tirosh, J. (1985). Rupture instability in hydro-forming deep-drawing process. International Journal of Mechanical Sciences, 27(9), 559-570. https://doi.org/10.1016/0020-7403(85)90072-4
- Yossifon, S., & Tirosh, J. (1988). On the Permissible Fluid-Pressure Path in Hydro-forming Deep Drawing Processes-Analysis of Failures and Experiments. Journal of Engineering for Industry, 110 (2), 146-152. https://doi.org/10.1115/1.3187863
- Zhang, S. H., & Danckert, J. (1998). Development of hydro-mechanical deep drawing. Journal of Material Processing Technology, 83(1-3), 14-25.https://doi.org/10.1016/S0924-0136(98)00039-9