Manufacturing Technology 2017, 17(4):597-602 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/4/597

Finite Element Analysis of Counterbore-shaped Parts by Using Sheet-bulk Metal Forming Process

Sutasn Thipprakmas1, Arkarapon Sontamino2, Wiriyakorn Phanitwong1
1 Department of Tool and Materials Engineering, King Mongkut's University of Technology Thonburi, Thailand
2 Graduate student, Dept. of Tool and Materials Engineering, King Mongkut's University of Technology Thonburi, Bangkok, Thailand

The merits of metal-forming process, as compared to the material removal process, are a good utilization of material and shorten the production time. To fabricate the complex shaped parts, it is increasingly applied. As a particular type of metal-forming process, to produce counterbore-shaped parts, the sheet-bulk metal forming which controls the flow of material into special punch and die was investigated in the present study. The finite element method (FEM) was used as a tool to investigate the sheet-bulk metal forming mechanism and their defects occurred during process. The sheet-bulk metal forming mechanism and poor squareness defect were clearly identified via the changes of the material flow and stress distribution analyses. In addition, the relationships between forged punch diameter and limitation of material thickness and hole diameter changes after forging were also investigated. Laboratory pressing experiments were performed to validate the accuracy of the FEM simulation results. The FEM simulation results showed good agreement with the experimental results with regards to the dimensions of the cut surface in the punching operation and counterbore shape in the sheet-forging operation.

Keywords: Sheet-bulk metal forming; Sheet-forging; Punching; Counterbore; Finite Element Analysis

Published: September 1, 2017  Show citation

ACS AIP APA ASA Harvard Chicago IEEE ISO690 MLA NLM Turabian Vancouver
Thipprakmas S, Sontamino A, Phanitwong W. Finite Element Analysis of Counterbore-shaped Parts by Using Sheet-bulk Metal Forming Process. Manufacturing Technology. 2017;17(4):597-602. doi: 10.21062/ujep/x.2017/a/1213-2489/MT/17/4/597.
Share...
Download citation
  • BibTeX (.bib)
  • Bookends (.ris)
  • EasyBib (.ris)
  • EndNote (.enw)
  • EndNote 8 (.xml)
  • ISI WoS (.isi)
  • Medlars (.medlars)
  • Mendeley (.ris)
  • MODS (.xml)
  • Papers (.ris)
  • RefWorks (.txt)
  • RefManager (.ris)
  • RIS (.ris)
  • MS Word (.xml)
  • Zotero (.ris)
    • Open article abstract

    References

    1. CHEN, Z. H., TANG, C. Y., CHAN, L. C. et al. (1999). Simulation of the sheet extrusion process by the enhanced assumed strain finite element method, J. Mater. Process Technol. 91:250-256. Go to original source...
    2. CHEN, F. K., HUANG, T. B., WANG, S. J. (2007). A study of flow-through phenomenon in the press forging of magnesium-alloy sheets, J. Mater. Process. Technol. 187-188:770. Go to original source...
    3. GHASSEMALI, E., TAN, M. J., JARFORS, A. E. W. et al. (2013). Optimization of axisymmetric open-die micro-forging/extrusion processes: An upper bound approach, Int. J. Mech. Sci. 71:58-67. Go to original source...
    4. GONTARZ, A., PIESIAK, J. (2015). Determining the Normalized Cockroft-Latham Criterion for Titanium Alloy Ti6Al4V in Tensile Testing At Room Temperature, Proceedings of Proceedings of the World Congress on Mechanical, Chemical, and Material Engineering (MCM 2015), pp. 248 (1-4), International ASET Inc.
    5. HIROTA, K. (2007). Fabrication of micro-billet by sheet extrusion, J. Mater. Process. Technol. 191:283-287. Go to original source...
    6. JENÍÈEK, S., VOREL, I., KÁÒA, J., OPATOVÁ, K. (2017). The use of material-technological modelling to determine the effect of temperature and amount of deformation on microstructure evolution in a closed-die forging treated by controlled cooling, Manufacturing Technology, 17(3): 326-330. Go to original source...
    7. KALPAKJIAN, S., SCHMID, S. (2006). Manufacturing Engineering and Technology, Prentice Hall, Singapore, 6th edition.
    8. LANGE, K., (1985). Handbook of metal forming. McGraw-Hill Inc., New York.
    9. LOU, S., WANG, Y., LU, S., SU, C. (2016). Extrusion process parameters optimization for the aluminum profile extrusion of an upper beam on the train based on response surface methodology, Manufacturing Technology, 16(3): 551-557. Go to original source...
    10. PHANITWONG, W., THIPPRAKMAS, S. (2015). Finite element analysis of piping defect formation in the sheet-extrusion process, Int. J. Model. Simul. Sci. Comput. 6(1): 1550010 (10 pages) Go to original source...
    11. SCHULER (1998). Metal forming handbook. Springer, Berlin. Go to original source...
    12. THIPPRAKMAS, S., ROJANANAN, S., PARAMAPUTI, P. (2008). An investigation of step taper-shaped punch in piercing process using finite element method. J Mater Process Technol. 197:132-139. Go to original source...
    13. THIPPRAKMAS, S., PHANITWONG, W. (2010). Finite element analysis of shaving direction effects in reciprocating shaving process, Steel Res Int. 81(9), 1058-1061.
    14. THIPPRAKMAS, S., PHANITWONG, W. (2012). Finite element analysis of flange-forming direction in the hole flanging process, Int J Adv Manuf Tech. 61(5), 609-620. Go to original source...
    15. ZHENG, P. F., CHAN, L. C., LEE, T. C. (2005). Numerical analysis of the sheet metal extrusion, Finite Elem. Anal. Des. 42:189-207. Go to original source...
    16. ZHUANG, X. C., ZHAO, Z., XIANG, H. et al. (2008). Simulation of sheet metal extrusion processes with arbitrary Langrangian-Eulerian method, Trans. Nonferrous Met. Soc. China 18:1172-1176. Go to original source...

    Return to the content