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Finite element modelling of multi-point forming

Abosaf, Mohamed (2018)
Ph.D. thesis, University of Birmingham.

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Abstract

The general aim of this study is to develop a 3-D FE model for multi-point forming dies using ABAQUS software and use this to study the effect of process parameters related to tool geometry such as radius of curvature of deformed parts, pin size, elastic cushion thickness and coefficient of friction. Doubly curved parts will be investigated in this research. The material properties for two blanks were
determined for use as required parameters for the simulation analysis. Finite element models of the doubly curved forming process were developed and validated for two materials: DC05 steel sheet and 5251-0 aluminium sheet. The mesh sensitivity, reliability of the numerical model, suitable blank holder force, effect of gap distance between punch and blank holder on the thickness distribution, and
the comer defect were studied. A parametric study was carried to investigate the effect of certain parameters on the deviation from target shape, wrinkling, and thickness variation. A test rig for the experimental work was designed and manufactured. In parallel, experiments with the forming of doubly curved parts were conducted to validate the simulation results. The numerical analysis results were compared with the experimental results and good agreement was generally found. The methodology developed in this research could help to build a reliable numerical model to predict the common defects in sheet forming using the multi-point forming process.

Type of Work:Ph.D. thesis.
Supervisor(s):Pham, Duc Truong and Essa, Khamis
School/Faculty:Colleges (2008 onwards) > College of Engineering & Physical Sciences
Department:School of Engineering, Department of Mechanical Engineering
Subjects:TJ Mechanical engineering and machinery
Institution:University of Birmingham
ID Code:8012
This unpublished thesis/dissertation is copyright of the author and/or third parties. The intellectual property rights of the author or third parties in respect of this work are as defined by The Copyright Designs and Patents Act 1988 or as modified by any successor legislation. Any use made of information contained in this thesis/dissertation must be in accordance with that legislation and must be properly acknowledged. Further distribution or reproduction in any format is prohibited without the permission of the copyright holder.
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