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TECHNICAL PAPERS

Improving Formability in Sheet Metal Stamping With Active Drawbead Technology

[+] Author and Article Information
M. L. Bohn

Pactiv Corp., Canandaigua

S. G. Xu

Formability Analysis Dept., Metal Fabricating Division GM, Troy, MI

K. J. Weinmann, C. C. Chen

Department of Mechanical Engineering and Engineering Mechanics, Michigan Technological University, Houghton, MI 49931-1295

A. Chandra

Mechanical Engineering Department, Iowa State University, Ames, IA

J. Eng. Mater. Technol 123(4), 504-510 (Jul 24, 2000) (7 pages) doi:10.1115/1.1395577 History: Received July 24, 2000
Copyright © 2001 by ASME
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References

Ahmetoglu, M. A., Coremans, A., Kinzel, G. L., and Altan, T., 1993, “Improving Drawability by Using Variable Blank Holder Force and Pressure in Deep Drawing of Round and Nonsymmetric Parts,” SAE Paper No. 930287, Detroit, Michigan.
Nine, H. D., 1978, Drawbead Forces in Sheet Metal Forming, Mechanics of Sheet Metal Forming, D. P. Koistinen and N. M. Wang, eds., Plenum Press, pp. 179–211.
Tufekci, S. S., Wang, C. T., Kinzel, G. L., and Altan, T., 1994, “Estimation and Control of Drawbead Forces in Sheet Metal Forming,” SAE Paper No. 940941.
Xu, S. G., Bohn, M. L., and Weinmann, K. J., 1997, “Drawbeads in Sheet Metal Stamping,” SAE Paper No. 970986, Detroit, Michigan.
Cao, J., and Boyce, M. C., 1993, “Draw Bead Penetration as a Control Element of Material Flow,” SAE Paper No. 930517, Detroit, Michigan.
Michler,  J. R., Weinmann,  K. J., Kashani,  A. R., and Majlessi,  S. A., 1994, “A Strip-drawing Simulator with Computer-controlled Drawbead Penetration and Blankholder Pressure,” J. Mater. Process. Technol., 43, pp. 177–194.
Michler,  J. R., Bohn,  M. L., Kashani,  A. R., and Weinmann,  K. J., 1995, “Feedback Control of the Sheet Metal Forming Process Using Drawbead Penetration as the Control Variable,” Trans. NAMRI/SME, XXIII, pp. 71–76.
Xu,  S. G., and Weinmann,  K. J., 1996, “An Investigation of Drawbead Control in Rectangular Box Forming by Finite Element Modeling,” Trans. NAMRI/SME, XXIV, pp. 137–142.
Li,  R., Weinmann,  K. J., and Chandra,  A., 1999, “The Use of Active Drawbeads in the Forming of Non-symmetric Aluminum Panels,” Trans. NAMRI/SME, XXVII, pp. 13–18.
Bohn, M. L., Jurthe, S. U., and Weinmann, K. J., 1998, “A New Multi-point Active Drawbead Forming Die: Model Development for Process Optimization,” SAE Paper No. 980076, Detroit, Michigan.
Xu, S. G., 1998, “On the Formability of Sheet Metals—Part A: Predition of Forming Limits Based on Hill’s 1993 Yield Criterion, Part B: Effect of Drawbeads on Sheet Formability,” Ph.D. dissertation, Michigan Technological University.
Bohn, M. L., Weinmann, K. J., and Michler, J. R., 1996, “A New Concept for a Hydro-Mechanical Press Conversion for Sheet Metal Forming Research,” Technical Papers of NAMRI/SME, pp. 95–99.
Bohn,  M. L., and Weinmann,  K. J., 2000, “Open Loop Optimization of the Sheet Metal Drawing Process with Active Drawbeads,” Trans. NAMRI/SME, XXVIII, pp. 21–26.
Shivpuri, R., 2000, Personal Communication.
Graf,  A., and Hosford,  W., 1994, “The Influence of Strain Path Changes on Forming Limit Diagrams of A16111-T4,” Int. J. Mech. Sci., 36, pp. 897–910.

Figures

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6111-T4 aluminum test panel
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Schematic view of drawing tooling
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Drawbead trajectories for open-loop investigation
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Quarter panel showing grid circle locations for viscoplastic strain analysis
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Finite element model (quarter panel) for oval die
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Punch load curves for trajectories 1–4 compared to the baseline of 5 mm constant penetration
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Experimental (top) and predicted (bottom) strains in Zone A for variable drawbead penetration cases 1 through 4, and 5 mm constant penetration
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Experimental (top) and predicted (bottom) strains in Zone B for variable drawbead penetration cases 1 through 4, and 5 mm constant penetration
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Experimental (top) and predicted (bottom) strains in Zone C for variable drawbead penetration cases 1 through 4, and 5 mm constant penetration
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Experimental (top) and predicted (bottom) strains in Zone D for variable drawbead penetration cases 1 through 4, and 5 mm constant penetration
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Measured strain on deformed panel for drawbead Case T1, compared to experimental FLD for 6111-T4 aluminum
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Measured strain on deformed panel for drawbead Case T50, compared to experimental FLD for 6111-T4 aluminum.
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Deformed part showing regions of punch face covered by each strain circle
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Measured strains on left side (C1) of punch face in length (parallel to drawbeads) and width directions
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Measured strains on right side (C3) of punch face in length (parallel to drawbeads) and width directions
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Measured strains on center (C2) of punch face in length (parallel to drawbeads) and width directions

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