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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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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