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A Study on Wear at the Entrance of the Draw-die of Sheet Metal Stamping and Optimization

Author: WangJinZuo
Tutor: YangXuJing
School: Hunan University
Course: Mechanical Engineering
Keywords: Sheet Metal Stamping Optimization Die Entrance Wear
CLC: TG385
Type: Master's thesis
Year: 2013
Downloads: 18
Quote: 0
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Abstract


Die life is one of the important factors which directly affect the product quality,efficiency and cost of products. And wear is the major form of mold invalidation. Toolwear directly impacts the die life and causes many defects such as skid line and gall-ing, thereby reducing product quality.Generally speaking, wear occurs mainly in the die entrance of sheet metalstamping, therefore it is of significant meanings to study the wear at the die entrance.The main work in this paper is concluded as follows:(1) Present two wear basic models by researching on the basic theory of wearaccording to the analysis results of the mechanism of galling defect.(2) Perform a detailed discussion on the contact pressure at the die entrance ofsquare-box and investigate wear by the Archard wear model.(3) In order to clearly summarize the effects of process parameters on the weardistribution at the die entrance, a parametric study is made via the numerical simula-tion on the stamping of the square-box, including blank holder force, tool-to-sheetclearance and blank thickness. The results show that too-to-sheet clearance and punchvelocity have only a minor influence while the blank holder force and blank thicknesshave obvious effect on the wear distribution at the die entrance.(4) The influence of various die entrance profiles on the tool wear is investigat-ed. It is found that the geometry shape of draw die entrance has a significant influenceon the tool wear. For standard circular profiles, the maximum wear drops significantlywhen the radius increases. For high elliptical profiles, the most critical tool wear workis located at the area near0°. The high elliptical profile produce low wear work during90%of the die entrance zones than the standard circular profile. For low ellipticalprofiles, the area near90°is the critical position where the maximum wear of happens.(5) Propose a new method of using cubic spline curve to design the draw-dieprofile. With the forming quality requirement, this paper presents an attempt to reducetool wear using the finite-element method and a general optimization technique tore-design the geometry of the draw-die profile of a deep-drawing with respect tominimize the tool wear. Finally, the optimization design method of the draw-die pro-file is applied to hood outer of car. The results of the square-box and the hood outer ofcar show that tool wear is obviously reduced and is well distributed over the die en-trance by using the optimized uniform cubic B-splines profile. Consequently, the quality of the sheet metal surface is improved, and the life of tool is extended.The research results indicate that the new method of using cubic spline curve asthe draw-die profile can significantly reduce the tool wear and provides a new designmethod of draw-die profile in sheet metal stamping.

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CLC: > Industrial Technology > Metallurgy and Metal Craft > Metal pressure processing > Cold stamping ( sheet metal processing) > Cold punching machinery and equipment
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