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TECHNICAL PAPERS

Sheet Metal Forming Using Polymer Composite Rapid Prototype Tooling

[+] Author and Article Information
Y. Park, J. S. Colton

The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405

J. Eng. Mater. Technol 125(3), 247-255 (Jul 10, 2003) (9 pages) doi:10.1115/1.1543971 History: Received October 15, 2001; Revised July 02, 2002; Online July 10, 2003
Copyright © 2003 by ASME
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References

Keeler, S. P., 1978, “Sheet Metal Stamping Technology—Need for Fundamental Understanding,” Mechanics of Sheet Metal Forming: Material Behavior and Deformation Analysis, Koistinen and Wang, eds., Plenum Press, New York, NY, pp. 3–18.
Miller, W., 1999, “Producing Dies for Rapid Prototyping of Metal Formed Parts,” The Fabricator, 29 (4), Fabricators and Manufacturers Association International (FMA), pp. 44–47.
Altan,  T., and Vazquez,  V., 1996, “Numerical Process Simulation for Tool and Process Design in Bulk Metal Forming,” CIRP Ann., 45(2), pp. 599–615.
Knoerr,  M., Lange,  K., and Altan,  T., 1994, “Fatigue Failure of Cold Forging Tooling: Causes and Possible Solutions Through Fatigue Analysis,” J. Mater. Process. Technol., 46, pp. 57–71.
Geiger, M., Hansel, M., and Rebhan, T., 1992, “Improving the Fatigue Resistance of Cold Forging Tools by FE Simulation and Computer Aided Die Shape Optimization,” IMechE, Part B: Journal of Engineering Manufacture, 206 , pp. 143–150.
Falk,  B., Engel,  U., and Geiger,  M., 1998, “Estimation of Tool Life in Bulk Metal Forming Based on Different Failure Concepts,” J. Mater. Process. Technol., 80–81, pp. 602–607.
Jensen,  M. R., Damborg,  F. F., Nielsen,  K. B., and Danckert,  J., 1998, “Applying the Finite-Element Method for Determination of Tool Wear in Conventional Deep-Drawing,” J. Mater. Process. Technol., 83, pp. 98–105.
Ratner,  S. B., and Potapova,  L. B., 1991, “Multicycle Fatigue Resistance of Brittle Polymers,” Mech. Compos. Mater., 26(4), pp. 463–467.
Suresh, S., 1998, Fatigue of Materials, Cambridge University Press, Cambridge, UK.
Ritchie,  R. O., Gilbert,  J. M., and McNaney,  J. M., 2000, “Mechanics and Mechanisms of Fatigue Damage and Crack Growth in Advanced Materials,” Int. J. Solids Struct., 37(1), pp. 311–329.
Tadmor, Z., and Gogos, C. G., 1979, Principles of Polymer Processing, John Wiley and Sons, New York, NY.
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Figures

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Mechanical behavior of Ren Shape 5166: (a) stress-strain curves in tensile tests; and (b) load-deflection curves in flexural tests.
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Load-displacement curves in fracture toughness tests
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Stereomicroscopic fractographs of a fracture surface: (a) at 10X magnification; and (b) at 30X magnification.
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Friction coefficient versus normal load
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Finite element model with boundary conditions and mesh
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Maximum principal stress field in the die (magnified at the bend regions): (a) Ren Shape 5166; and (b) Steel.
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V-die bending experimental setup
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Comparison of bending forces
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Strain gage locations and strain measurement directions
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Time history plot of maximum principal stress at bend region
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S-N data for Ren Shape 5166
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Magnified view at bend region: (a) schematics of punch-sheet-die interfaces; and (b) top view of “V” surface of the die after 1000 stamping cycles.
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Failure modes of V-bending dies: (a) after 5000 stamping cycles (Rb=5 mm, Fmax=8 kN); (b) after one stamping cycle (Rb=3 mm, Fmax=10 KN); and (c) after 507 stamping cycles (Rb=3 mm, Fmax=8 kN).

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