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Product, Tool, and Process Design Methodology for Deep Drawing and Stamping of Sheet Metal Parts

Thomas, William J.

Abstract Details

1999, Doctor of Philosophy, Ohio State University, Mechanical Engineering.
More powerful sheet metal forming design tools are needed to help engineers design better products and processes, to reduce lead times and costs, and to increase product performance and accuracy. With these issues in mind, the objectives of this dissertation are: • To develop a part and process design methodology for the deep drawing and stamping of sheet metal parts. • To generate computerized tools to aid engineers on the use of this proposed design methodology. The scope of this dissertation consists of: • Sheet metal parts ranging from cylindrical shells to complex automotive body panels. • Materials ranging from drawing quality steel, high strength steel, dent resistant steel, and aluminum alloys (2000, 3000, 5000, and 6000 series). The major research contributions and technologies that are associated with this dissertation are: • A mathematical model and computer software that allows engineers to calculate forming forces, formability limits, required tool geometry, and optimal process conditions (BHF profiles) for simple part geometries such as round cups, rectangular pans, U-channels, hemispherical shells, and asymmetric panels. • A module for commercial finite element method (FEM) programs that implements a feedback loop into the calculations (adaptive simulation) in order to determine optimal process conditions (BHF profiles) for general complex geometries. • Computerized tools that provide engineers with the effect of process parameters on part quality (sensitivity data) for various simple laboratory tool geometries using laboratory experiments and computer simulations. The prediction of optimal process parameters will focus primarily on determining the optimum time and spatial variation of the blank holder force (BHF) given a particular geometry. It has been proven in laboratories that drawability can be improved by changing the blank holder force during the stroke of the press (i.e. during deformation). Also, it has been observed that part quality can be enhanced by modifying the distribution of blank holder pressure (BHP) around the periphery of the blank. Thus, the question becomes given a certain geometry what is the optimum spatial distribution and time variation of the BHF? It is the goal of this work to contribute towards answering this question.
Taylan Altan (Advisor)
267 p.

Recommended Citations

Citations

  • Thomas, W. J. (1999). Product, Tool, and Process Design Methodology for Deep Drawing and Stamping of Sheet Metal Parts [Doctoral dissertation, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1380542371

    APA Style (7th edition)

  • Thomas, William. Product, Tool, and Process Design Methodology for Deep Drawing and Stamping of Sheet Metal Parts. 1999. Ohio State University, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1380542371.

    MLA Style (8th edition)

  • Thomas, William. "Product, Tool, and Process Design Methodology for Deep Drawing and Stamping of Sheet Metal Parts." Doctoral dissertation, Ohio State University, 1999. http://rave.ohiolink.edu/etdc/view?acc_num=osu1380542371

    Chicago Manual of Style (17th edition)