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
Your Session has timed out. Please sign back in to continue.


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.
Suchy, I., 1998, Handbook of Die Design, McGraw-Hill, New York, NY.
Kalpakjian, S., 1997, Manufacturing Processes for Engineering Materials, 3rd ed., Addison-Wesley, Menlo Park, CA.
American Society for Metals, 1985, Metals Handbook, ASM, Metals Park, OH.
Bannantine, J. A., Comer, J. J., and Handrock, J. L., 1990, Fundamentals of Metal Fatigue Analysis, Prentice Hall, Englewood Cliffs, NJ.
Adkins, D. W., and Kander, R. G., 1988, “Fatigue Performance of Glass Reinforced Thermoplastics,” Proceedings of the Fourth Annual Conference on Advanced Composites, Dearborn, MI, pp. 437–445.
Smith,  K. N., Watson,  P., and Topper,  T. H., 1970, “A Stress-Strain Function for the Fatigue of Metals,” J. Mater., 5(4), pp. 767–778.
American Society of Tool and Manufacturing Engineers, 1965, Die Design Handbook, 2nd ed., McGraw-Hill, New York, NY.


Grahic Jump Location
Mechanical behavior of Ren Shape 5166: (a) stress-strain curves in tensile tests; and (b) load-deflection curves in flexural tests.
Grahic Jump Location
Load-displacement curves in fracture toughness tests
Grahic Jump Location
Stereomicroscopic fractographs of a fracture surface: (a) at 10X magnification; and (b) at 30X magnification.
Grahic Jump Location
Friction coefficient versus normal load
Grahic Jump Location
V-die bending experimental setup
Grahic Jump Location
Comparison of bending forces
Grahic Jump Location
Strain gage locations and strain measurement directions
Grahic Jump Location
Time history plot of maximum principal stress at bend region
Grahic Jump Location
Finite element model with boundary conditions and mesh
Grahic Jump Location
Maximum principal stress field in the die (magnified at the bend regions): (a) Ren Shape 5166; and (b) Steel.
Grahic Jump Location
S-N data for Ren Shape 5166
Grahic Jump Location
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.
Grahic Jump Location
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).



Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In