The Experts below are selected from a list of 29646 Experts worldwide ranked by ideXlab platform
Huajie Mao - One of the best experts on this subject based on the ideXlab platform.
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investigation of a novel modified die design for Fine Blanking process to reduce the die roll size
Journal of Materials Processing Technology, 2018Co-Authors: Yanxiong Liu, Li Hua, O Tang, Huajie MaoAbstract:Abstract In order to reduce the die-roll size in the Fine-Blanking process, a modified die structure was proposed, which an indenter arranged along the die profile was set on the cutting edge. The indenter can be deFined by four structure parameters. To investigate the effect of these four die structure parameters and evaluate their degree of importance on the die-roll size, three different levels of each die structure parameter were applied in the Fine-Blanking process of a specially designed triangular tooth using FEM. The optimized die structures were determined considering the effect of reducing die-roll size, the die lifetime and the prevention of crack on the cutting surface. Extra simulations were carried out to verify the effect of the modified die. To explain the mechanism of the modified die, a theoretical model was established according to the features of die structures. The former FEM results were taken as examples to demonstrate the theoretical model. To test the feasibility of this modified die, experiments were performed on the part of automobile synchronizer slipper. In addition, the relationship between the blank holder force and the die-roll sizes in the different Fine-Blanking processes was studied during the experiments.
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investigation of a novel modified die design for Fine Blanking process to reduce the die roll size
Procedia Engineering, 2017Co-Authors: O Tang, Yanxiong Liu, Huajie MaoAbstract:Abstract Fine-Blanking is known as an effective sheet metal forming process to obtain precisely blanked parts with smooth cutting surface. However, the die-roll occurred in the sharp area is an inevitable problem which decreases the working performance and service life of the part. In order to reduce the die-roll size, a modified die design for Fine-Blanking process was proposed. The cutting edge of the die is set on an indenter arranged along the sharp area, while in the conventional die design, cutting edge is set on the die directly according to the part outline. The finite element method was used to optimize the die structure. The material flow was studied to explain the mechanism of the modified die design compared to the conventional die. The results of the FE-simulation were applied in the production of the automobile synchronizer. This part has four sharp areas where big die-roll occurs easily and yet it requires small die-roll sizes strictly. The experiment results proved that this novel die design was quite effective to reduce the die-roll size, which showed a promising application in future real practice.
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numerical and experimental investigation of the discontinuous dot indenter in the Fine Blanking process
Journal of Manufacturing Processes, 2016Co-Authors: Huajie Mao, Yanxiong Liu, Fei Zhou, Li HuaAbstract:Abstract The Fine-Blanking process has been widely applied in industries to produce clean-cut surface parts. The V-ring indenter blank holder, which is an essential part of the Fine-Blanking tool, is notably important in increasing the cutting surface quality of blanked parts. Because the V-ring indenter is difficult to manufacture, it is difficult to ensure the machining accuracy, and the cost is notably high. In this study, a new discontinuous dot indenter blank holder is presented. The discontinuous dot indenter blank holder can improve the quality of the Fine-blanked surface, which is identical to that of the V-ring indenter, but the manufacture process is notably easy, and the cost is notably low. The hydrostatic stress, material flow and quality of the Fine-blanked surface in the Fine-Blanking process were analyzed to reveal the discontinuous dot indenter mechanism. To obtain a larger burnished zone, the finite-element (FE) simulation and ANOVA technique were applied to optimize the discontinuous dot indenter parameters, i.e., dot diameters, fillet radius, distributions, positions and heights. Next, these optimal parameters were applied to Fine-blank a spur gear, and the experiment results have a good agreement with the FE simulation results. Moreover, the results also indicate that the discontinuous dot indenter can be used in the Fine-Blanking process to obtain almost full clean-cut surface parts.
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finite element analysis and topology optimization of a 12000kn Fine Blanking press frame
Structural and Multidisciplinary Optimization, 2016Co-Authors: Xinhao Zhao, Yanxiong Liu, Li Hua, Huajie MaoAbstract:Fine Blanking press frame is one of the core components of the Fine Blanking press. Good performance of the frame is of great importance to ensure Blanking precision. Simultaneously, lightweight of the frame would decrease the total press weight, and reduce the consumption of manufacturing and transportation. In this paper, the topology optimization technology was used to optimize a 12000KN Fine Blanking press frame. Firstly, a finite element model was established to analyze the original 12000KN Fine Blanking press frame. The proper way of finite element modelling was determined by an experiment. Then, an optimization problem was formulated using Solid Isotropic Microstructures with Penalization (SIMP) method. After that, a testing topology optimization was conducted, whose result revealed some complex, non-manufacturable design features. To cope with these exposed issues and obtain a result with clearer configuration and better manufacturability, a two-stage optimization procedure was proposed, in which manufacturing constraints played an important role. Ultimately, an optimized CAD model for the frame was constructed, and finite element analysis showed that 13.66 % volume reduction was achieved while the performance slightly increased compared with the original frame.
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finite element simulation of effect of part shape on forming quality in Fine Blanking process
Procedia Engineering, 2014Co-Authors: Yanxiong Liu, Li Hua, Huajie Mao, Wei FengAbstract:Abstract Fine-Blanking as an effective and economical sheet metal cutting process has been widely used in the precision machines, automobiles, electronics and aircraft areas. This process can produce smooth-sheared edges over the full workpiece thickness in one single operation with the optimized process parameters. However, the crack phenomenon always occurred in the Fine-Blanking process when the part shape is complicated. The forming quality of the part with concave and convex shape has been investigated with finite element simulation and experiment methods. In order to reveal the effect of part shape on the Fine-Blanking process comprehensively, a simple finite element model in which the part has convex and concave shape were created. The effects of the angle between the neighbouring edges and height of the convex and concave on the surface quality have been investigated. Furthermore, the way to design the parameters for parts with complicated shape has been discussed in this paper.
Sutasn Thipprakmas - One of the best experts on this subject based on the ideXlab platform.
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application of taguchi technique to investigation of geometry and position of v ring indenter in Fine Blanking process
Materials & Design, 2010Co-Authors: Sutasn ThipprakmasAbstract:One of the special features of the Fine-Blanking process is the use of the V-ring indenter. The V-ring geometry, namely its angle and height, in addition to its position, affects features of the Fine-blanked surface. In this study, the finite element (FE) simulation, the Taguchi technique, and the analysis of variance (ANOVA) techniques were carried out to investigate the degree of importance of V-ring indenter parameters. The results indicated that the height and position of the V-ring indenter have a major influence on the Fine-Blanking process, followed by the V-ring indenter angle. The combination of the FE-simulation, the Taguchi method, and the ANOVA technique was an effective tool to predict the degree of importance of the V-ring indenter parameters in the Fine-Blanking process, in addition to facilitating an improvement in the quality of the Fine-blanked parts by optimization of these V-ring indenter parameters.
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investigation mechanism of v ring indenter geometry in Fine Blanking process
Key Engineering Materials, 2009Co-Authors: Sutasn ThipprakmasAbstract:The V-ring indenter geometry (angle, height and position) was investigated by using the finite element method (FEM) to theoretically clarify the mechanism and its action in the Fine-Blanking process. The FEM simulation results indicate that very small or very large V-ring indenter angles, heights, and positions cause difficulty in the rotation of the material-flow and that the hydrostatic pressure is generated with great difficulty in the blanked material; therefore, crack formation occurs easily. The application of a suitable V-ring indenter angle, height, and position significantly suppresses the formation of rotating flow, which results in increased hydrostatic pressure, and crack formation is consequently prevented.
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finite element analysis of v ring indenter mechanism in Fine Blanking process
Materials & Design, 2009Co-Authors: Sutasn ThipprakmasAbstract:In Fine-Blanking process, V-ring indenter is very important in increasing the edge quality of the blanked part. Previous research in this field was mainly experiment-based; therefore, the theoretical mechanism was not clarified. In this study, the V-ring indenter mechanism was investigated using the finite element method. The mechanism and effects of the V-ring indenter could be theoretically clarified on the basis of material flow analysis and stress distribution. The application of the V-ring indenter increased compressive stress before the cutting phase, and significantly suppressed the increased rotation of material flow during the cutting phase. This, in turn, caused increased hydrostatic compressive stress, resulting in a larger smooth cut surface.
Sung Ho Chang - One of the best experts on this subject based on the ideXlab platform.
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a study on the effect of v ring position on the die roll height in Fine Blanking for special automobile seat recliner gear
Advanced Materials Research, 2011Co-Authors: Jong Deok Kim, H K Kim, Young Moo Heo, Sung Ho ChangAbstract:In this paper, the relation between die roll height and V-ring position was studied by Fine Blanking experiments for imaginary special automobile seat recliner gear. The three die inserts and three guide plate inserts with different V-ring positions were machined, and Fine Blanking tool was manufactured. Using the Fine Blanking tool, three experiments were conducted on the 650 ton Fine Blanking press. Each die roll height was measured, analyzed and we found the tendency of die roll heights on imaginary special gear to increase with increasing the distance between V-ring position and contour of gear. This result can be used to minimize the die roll height of Fine Blanking gear parts when designing V-ring of Fine Blanking tool.
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a study on die roll height of special automobile seat recliner gear according to die chamfer shape in Fine Blanking tool
Applied Mechanics and Materials, 2011Co-Authors: Jong Deok Kim, H K Kim, Young Moo Heo, Sung Ho ChangAbstract:In this paper, the effect of die chamfer shape on the die roll height was studied by Fine Blanking experiments for imaginary special automobile seat recliner gear. The three die inserts with different die chamfer shapes were machined, and Fine Blanking tool was manufactured. Using the Fine Blanking tool, three experiments were conducted on the 650 ton Fine Blanking press. Each die roll height was measured, analyzed and we found the tendency of die roll heights on imaginary special automobile seat recliner gear to increase with increasing die chamfer angle, with the horizontal distance of die chamfer being constant. This result can be used to minimize the die roll height of Fine Blanking gear parts when designing die chamfer of Fine Blanking tool.
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a study on the relation between die roll height and die chamfer shape in Fine Blanking for special gear
Advanced Materials Research, 2011Co-Authors: Jong Deok Kim, H K Kim, Young Moo Heo, Sung Ho ChangAbstract:In this paper, the relation between die roll height and die chamfer shape was studied by Fine Blanking experiments for imaginary special gear. The three die inserts with different die chamfer shapes were machined, and Fine Blanking tool was manufactured. Using the Fine Blanking tool, three experiments were conducted on the 650 ton Fine Blanking press. Each die roll height was measured, analyzed and we found the tendency of die roll heights on imaginary special gear to increase with increasing die chamfer angle, with the horizontal distance of die chamfer being constant. This result can be used to minimize the die roll height of Fine Blanking gear parts when designing die chamfer of Fine Blanking tool.
Fritz Klocke - One of the best experts on this subject based on the ideXlab platform.
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dependencies of the die roll height during Fine Blanking of case hardening steel 16mncr5 without v ring using a nesting strategy an experimental analysis of the influences of nesting sheet metal anisotropy stroke number and part geometry
The International Journal of Advanced Manufacturing Technology, 2018Co-Authors: H Voigts, Andreas Feuerhack, Daniel Trauth, P Mattfeld, Fritz KlockeAbstract:For economic reasons, Fine Blanking of asymmetric parts is performed with shifted and rotated part nesting. It was observed that both the part position and the part orientation on the sheet metal strip affect the die-roll height. Therefore, the influence of the bridge width between the produced cutting line and the strip edge or existing sheared edges was studied in this work. Additionally, the effects of the stroke number, the convexity of the radii and the sheet metal anisotropy were considered. The parts were manufactured in a production series of 40,000 parts with a Fine Blanking tool ejecting four parts simultaneously. From each nest, 20 parts were separated at four equidistant steps. The die-roll height was determined in three regions with different convexity radii of parts from varying nests. A normal distribution was found for the die-roll height, categorized by convexity radius and position of the nest. The die-roll height was found to be promoted by convexity radius, small bridge width, and in transverse blank direction. The number of strokes had a minor impact. Interaction effects occur particularly at small convexity radii and small bridge widths. As a conclusion, the nesting must be considered in order to reduce the die-roll height. Small bridge widths, small convexity radii, and the orientation in transverse blank direction have a negative impact, whereas the stroke number has a marginal influence. The understanding of the correlation between die-roll formation and nesting helps to reduce waste in mass manufacturing.
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a characterization of quality of sheared edge in Fine Blanking using edge computing approach
Procedia Manufacturing, 2018Co-Authors: Daniel Trauth, Joachim Stanke, Andreas Feuerhack, Thomas Ergs, Patrick Mattfeld, Fritz KlockeAbstract:Abstract In Fine Blanking the sheared edge’s quality is of major importance. As the sheared edge needs to transmit process forces and precisely align parts, attributes like die rolls, tears and tear-offs need to be eliminated. Currently, these attributes are manually determined at the end of the process chain, which makes a complete correlation between influencing factors and the attributes hardly possible. If it would be possible to create a real-time evaluation of the attributes, not only unknown correlations would be found, also an instant process adaption could be made, optimizing the quality of the sheared edge. Therefore, this contribution focusses on the development of an edge computing approach.
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a predictive model for die roll height in Fine Blanking using machine learning methods
Procedia Manufacturing, 2018Co-Authors: Joachim Stanke, Daniel Trauth, Andreas Feuerhack, Patrick Mattfeld, Fritz KlockeAbstract:Abstract A method for the development of a predictive model for the die roll height in Fine Blanking using artificial neural networks and support vector machines is presented. Since artificial neural networks require big amounts of training data and generation using experiments is very time consuming and cost intensive, a validated FE model is used instead. The required training data will be determined using learning curves. The optimal architecture and hyperparameter of the artificial neural network will be derived. Additionally, the die roll height is modelled using support vector machines and also conventional statistical regression models. Finally the accuracy of the methods is compared.
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setup of a parameterized fe model for the die roll prediction in Fine Blanking using artificial neural networks
36th IDDRG Conference - Materials Modelling and Testing for Sheet Metal Forming, 2017Co-Authors: Joachim Stanke, Daniel Trauth, Andreas Feuerhack, Fritz KlockeAbstract:Die roll is a morphological feature of Fine blanked sheared edges. The die roll reduces the functional part of the sheared edge. To compensate for the die roll thicker sheet metal strips and secondary machining must be used. However, in order to avoid this, the influence of various Fine Blanking process parameters on the die roll has been experimentally and numerically studied, but there is still a lack of knowledge on the effects of some factors and especially factor interactions on the die roll. Recent changes in the field of artificial intelligence motivate the hybrid use of the finite element method and artificial neural networks to account for these non-considered parameters. Therefore, a set of simulations using a validated finite element model of Fine Blanking is firstly used to train an artificial neural network. Then the artificial neural network is trained with thousands of experimental trials. Thus, the objective of this contribution is to develop an artificial neural network that reliably predicts the die roll. Therefore, in this contribution, the setup of a fully parameterized 2D FE model is presented that will be used for batch training of an artificial neural network. The FE model enables an automatic variation of the edge radii of blank punch and die plate, the counter and blank holder force, the sheet metal thickness and part diameter, V-ring height and position, cutting velocity as well as material parameters covered by the Hensel-Spittel model for 16MnCr5 (1.7131, AISI/SAE 5115). The FE model is validated using experimental trails. The results of this contribution is a FE model suitable to perform 9.623 simulations and to pass the simulated die roll width and height automatically to an artificial neural network.
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Finite element simulation of an analogy process for the Fine Blanking of helical gears
2011 IEEE International Symposium on Assembly and Manufacturing (ISAM), 2011Co-Authors: Fritz Klocke, Vladimir Bäcker, M. Zimmermann, Hagen WegnerAbstract:Fine Blanking can today be used for the production of spur gears but not for helical gears. Based on a newly developed process principle for the Fine Blanking of helical gears, an analogy process was set up and investigated in finite element simulations using the software Deform-3D. For the numerical model, the tool components were assumed rigid, while workpiece behavior was modeled as plastic with isotropic strain hardening. Damage initiation was included by using a normalized formulation of the Cockroft and Latham damage criterion. Results show, that sheet thickness and helix angle are key influence factors for the final workpiece properties as well as for the stress distribution in the workpiece during the process. Their influence varies with respect to the tooth section, i.e. tooth flanks and tooth tip.
Yanxiong Liu - One of the best experts on this subject based on the ideXlab platform.
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investigation of a novel modified die design for Fine Blanking process to reduce the die roll size
Journal of Materials Processing Technology, 2018Co-Authors: Yanxiong Liu, Li Hua, O Tang, Huajie MaoAbstract:Abstract In order to reduce the die-roll size in the Fine-Blanking process, a modified die structure was proposed, which an indenter arranged along the die profile was set on the cutting edge. The indenter can be deFined by four structure parameters. To investigate the effect of these four die structure parameters and evaluate their degree of importance on the die-roll size, three different levels of each die structure parameter were applied in the Fine-Blanking process of a specially designed triangular tooth using FEM. The optimized die structures were determined considering the effect of reducing die-roll size, the die lifetime and the prevention of crack on the cutting surface. Extra simulations were carried out to verify the effect of the modified die. To explain the mechanism of the modified die, a theoretical model was established according to the features of die structures. The former FEM results were taken as examples to demonstrate the theoretical model. To test the feasibility of this modified die, experiments were performed on the part of automobile synchronizer slipper. In addition, the relationship between the blank holder force and the die-roll sizes in the different Fine-Blanking processes was studied during the experiments.
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investigation of a novel modified die design for Fine Blanking process to reduce the die roll size
Procedia Engineering, 2017Co-Authors: O Tang, Yanxiong Liu, Huajie MaoAbstract:Abstract Fine-Blanking is known as an effective sheet metal forming process to obtain precisely blanked parts with smooth cutting surface. However, the die-roll occurred in the sharp area is an inevitable problem which decreases the working performance and service life of the part. In order to reduce the die-roll size, a modified die design for Fine-Blanking process was proposed. The cutting edge of the die is set on an indenter arranged along the sharp area, while in the conventional die design, cutting edge is set on the die directly according to the part outline. The finite element method was used to optimize the die structure. The material flow was studied to explain the mechanism of the modified die design compared to the conventional die. The results of the FE-simulation were applied in the production of the automobile synchronizer. This part has four sharp areas where big die-roll occurs easily and yet it requires small die-roll sizes strictly. The experiment results proved that this novel die design was quite effective to reduce the die-roll size, which showed a promising application in future real practice.
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numerical and experimental investigation of the discontinuous dot indenter in the Fine Blanking process
Journal of Manufacturing Processes, 2016Co-Authors: Huajie Mao, Yanxiong Liu, Fei Zhou, Li HuaAbstract:Abstract The Fine-Blanking process has been widely applied in industries to produce clean-cut surface parts. The V-ring indenter blank holder, which is an essential part of the Fine-Blanking tool, is notably important in increasing the cutting surface quality of blanked parts. Because the V-ring indenter is difficult to manufacture, it is difficult to ensure the machining accuracy, and the cost is notably high. In this study, a new discontinuous dot indenter blank holder is presented. The discontinuous dot indenter blank holder can improve the quality of the Fine-blanked surface, which is identical to that of the V-ring indenter, but the manufacture process is notably easy, and the cost is notably low. The hydrostatic stress, material flow and quality of the Fine-blanked surface in the Fine-Blanking process were analyzed to reveal the discontinuous dot indenter mechanism. To obtain a larger burnished zone, the finite-element (FE) simulation and ANOVA technique were applied to optimize the discontinuous dot indenter parameters, i.e., dot diameters, fillet radius, distributions, positions and heights. Next, these optimal parameters were applied to Fine-blank a spur gear, and the experiment results have a good agreement with the FE simulation results. Moreover, the results also indicate that the discontinuous dot indenter can be used in the Fine-Blanking process to obtain almost full clean-cut surface parts.
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finite element analysis and topology optimization of a 12000kn Fine Blanking press frame
Structural and Multidisciplinary Optimization, 2016Co-Authors: Xinhao Zhao, Yanxiong Liu, Li Hua, Huajie MaoAbstract:Fine Blanking press frame is one of the core components of the Fine Blanking press. Good performance of the frame is of great importance to ensure Blanking precision. Simultaneously, lightweight of the frame would decrease the total press weight, and reduce the consumption of manufacturing and transportation. In this paper, the topology optimization technology was used to optimize a 12000KN Fine Blanking press frame. Firstly, a finite element model was established to analyze the original 12000KN Fine Blanking press frame. The proper way of finite element modelling was determined by an experiment. Then, an optimization problem was formulated using Solid Isotropic Microstructures with Penalization (SIMP) method. After that, a testing topology optimization was conducted, whose result revealed some complex, non-manufacturable design features. To cope with these exposed issues and obtain a result with clearer configuration and better manufacturability, a two-stage optimization procedure was proposed, in which manufacturing constraints played an important role. Ultimately, an optimized CAD model for the frame was constructed, and finite element analysis showed that 13.66 % volume reduction was achieved while the performance slightly increased compared with the original frame.
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finite element simulation of effect of part shape on forming quality in Fine Blanking process
Procedia Engineering, 2014Co-Authors: Yanxiong Liu, Li Hua, Huajie Mao, Wei FengAbstract:Abstract Fine-Blanking as an effective and economical sheet metal cutting process has been widely used in the precision machines, automobiles, electronics and aircraft areas. This process can produce smooth-sheared edges over the full workpiece thickness in one single operation with the optimized process parameters. However, the crack phenomenon always occurred in the Fine-Blanking process when the part shape is complicated. The forming quality of the part with concave and convex shape has been investigated with finite element simulation and experiment methods. In order to reveal the effect of part shape on the Fine-Blanking process comprehensively, a simple finite element model in which the part has convex and concave shape were created. The effects of the angle between the neighbouring edges and height of the convex and concave on the surface quality have been investigated. Furthermore, the way to design the parameters for parts with complicated shape has been discussed in this paper.