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Development of a robust method to accomodate springback distortion in multistage sheet metal forming

Omar, Badrul and Siswanto, Waluyo Adi and Anggono, Agus Dwi (2011) Development of a robust method to accomodate springback distortion in multistage sheet metal forming. Other thesis, Universiti Tun Hussein Onn Malaysia.

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Numerical simulation by finite element method has become a powerful tool in preventing the unwanted effects of sheet metals technological processing. One of the most important problems in sheet metal forming is the compensation of springback. When stamped sheet components are removed from the forming tools, the residual internal stresses will relax, and a new equilibrium state will be reached. As a result, the final shape of the drawn part will deviate from the shape imposed by the forming tool. This phenomenon is known as springback. Springback phenomenon theoretically exists for anything kind of deep drawing or stamping process. In fact it is a well known and unwanted characteristic of every process that involves plastic deformations on elastic metals. To improve the accuracy of the formed parts, the die surfaces are required to be optimized so that after springback the geometry falls at the expected shape. Two methods of die compensation can be applied for this purpose; ~is~lacement~djustment (DA) and Karafillis and Boyce (K&B) methods. They are the so called spring-back compensation and spring-forward compensation. Both are based on an iterative procedure. The die compensation were studied by applied of both DA and K&B method. DA converges rapidly but its iterations may oscillate and K&B converges more slowly but iterations show steadily decreasing error. The combination of K&B 1 method and DA were applied with an improvement of the adjustment direction from y direction in original DA method to a normal vector of the surface to maintain the surface gap of lower and upper surface in a consistent way. The initial development of the hybrid algorithm is presented, a numerical test results on a simple model are also presented to support.

Item Type: Thesis (Other)
Subjects: T Technology > TJ Mechanical engineering and machinery
Depositing User: Normajihan Abd. Rahman
Date Deposited: 16 May 2013 08:38
Last Modified: 16 May 2013 08:38
URI: http://eprints.uthm.edu.my/id/eprint/3856
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