An approach for automated detection of sidewall wrinkling in FEA has been developed and tested for a conical cup and a fender shaped component geometry at IFU. Therefore, several wrinkling criteria have been investigated, evaluated and finally, sidewall wrinkling identification based on strain ratios φ1 / φ2 in forming limit diagram has been chosen and implemented in FEA. Within sensitivity analysis, identification of significant process input parameters and gradient of wrinkling limit curve is possible. Blank holder force represents a significant process input parameter. Gradient of wrinkling limit curve for fender shaped component geometry is φ1 / φ2 = -1.55 for mild steel DC04, draw depth 100 mm and initial blank thickness of 0.9 mm. Wrinkling limit curve was applied in batch-procedure for automated simultaneous optimization regarding failures cracks and sidewall wrinkling. Utilizing developed automated tool for virtual engineering, optimization with regard to failures cracks and sidewall wrinkling is possible at the same time prior to manufacturing of deepdrawing die. Optimization results show a defect free component. Material thinning has been reduced more than 25% compared to initial value. Thus, operational range can be enlarged and draw depth can be increased. Hence, feasibility of complex deep drawn component geometries has been improved. Visual investigation of optimization results with regard to occurrence of sidewall wrinkling is not necessary anymore. Results of robustness evaluation confirm functionality of automated detection of sidewall wrinkling within FEA.
Approaches for automated sidewall wrinkling detection in deep-drawing processes
2011
12 Seiten, 8 Bilder, 1 Tabelle, 19 Quellen
Aufsatz (Konferenz)
Englisch
Approaches for automated sidewall wrinkling detection in deep drawing processes
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