Computer aided analysis of sheet metal forming parts

Dissertant

al-Budayri, Ali Muhammad Jasim

Thesis advisor

Durubi, Ahmad A. A.
Khulayf, Ali Abbar

University

University of Technology

Faculty

-

Department

Department of Production Engineering and Metallurgy

University Country

Iraq

Degree

Master

Degree Date

2013

English Abstract

Stamping process is one of frequently used sheet metal forming processes, which was used in widespread industries, such as automotive parts industry, included doors, wheel caps, bumpers face bars,and roof panels, etc., which are more complex parts.

So that in an attempt to reduce developingtimes and costs, an integrated CAD/CAE/CAM systems have been established.

This thesisadopted two case studies, in which thedifferent development stages and procedures can be performed simultaneously to implement such that integration systems, and solving such problems of representation of free form surfaces and data exchanging process between various CAD,CAE, and CAM programs, also avoiding forming defects using FE analysis.

The 3D surface of the proposed case studieswas constructed using the developed procedure that can be represented the curves and surface of the objects without using CMM machine or reverse engineering approaches.Based on the outer control points,5th degree of B-Spline and Bezier approximation techniques were adopted to represent the curves and surfaces of the proposed case studies.Data file can be transfer into any other CAD program using the developed procedure without any distortion or noise.

The utilities of both MATLAB and UGS programs used in CAD system to achieve the developed procedure.

FEA was carried out to simulate the stamping process using ANSYS package, to study the stress distribution over the total displacement of the sheet.

The maximum simulated Von Misses stress for overall displacement that was obtained from simulation using analysis program, was compared with the maximum stress of 1070Aluminum sheetwhich is used as a workpiece, which obtained experimentally from tensile testto ensure validity of design.

UGS CAM program was used to generate the tool paths and NC part program of both die and punch surfaces.

The cutting simulation is performed to find out any potential problems,the range of spindle speed and feed rat from (700-1100rpm) and (50-70mmper min.) respectively for roughing, and (950rpm) and (100¬200mm per min.) for finishing give acceptable machining results for first case study.

While (1100rpm) spindle speed and(50mm per min.) feed rat give acceptable machining results for second case study.

These conditions are determined and examined with 3-axis CNC milling machine which used in the present thesis.

The result was a system, that can be used toimprove any other stamping parts, it can be greatly reduce the developmenttime and cost, reduce the cycle of design and manufacturing, and finally improve the product quality.

The proposed procedure to represent the suggested case studies model is able to represent any complex model without using the expensive CMM machine or reverse engineering approach.

Forming simulation helps to predict the formation of defects such as fracture, and modification are done at early stage before part is fabricated and tested.

Main Subjects

Engineering & Technology Sciences (Multidisciplinary)

Topics

• Data processing

• APA
• MLA
• AMA

Language

English

Data Type

Arab Theses

Record ID

BIM-413056