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Flexible forming of 3-D metal panels

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

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The process of sheet metal forming is commonly used to create 3-D surfaces in, e.g., aircrafts and automobiles. Stamping is one of most common sheet metal forming processes but traditional forming processes which have been developed for mass production are inflexible and expensive, and economically unsuitable for small-scale production. More appropriate for small-batch and prototype production are flexible forming methods such as multi-point forming (MPF) which have been developed in recent years. A pair of opposed reconfigurable tools containing pin matrices could replace traditional solid stamping tools. Based on this technique, the construction of sheet metal forming tools becomes flexible and fast.

Springback, caused by elastic recovery and release of residual stress, is an unavoidable issue in all sheet metal forming and significantly affects the geometrical precision of the products. Springback is a defect, and if it is beyond permissible tolerance it will adversely affect the assembly process such as distortion of sub-assemblies and poor fit-up during welding. Estimation of springback remains an important and challenging issue for the sheet metal industry.

Based on the ABAQUS software, 3-D finite element models were generated, with the required constraints and boundary conditions described and applied in the simulation. The process of multi-point forming and springback were simulated by combining explicit and implicit algorithms. The influence of some significant working parameters, such as radius of forming curvature, blank holder force and elastic cushion thickness on final product quality (springback, thickness variation and wrinkling) has been investigated.

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
Additional Information:

Elghawail, A., Essa, K., Abosaf, M., Tolipov, A., Su, S. and Pham, D., 2017. Prediction of springback in multi-point forming. Cogent Engineering, vol. 4, 1400507.

Subjects:TJ Mechanical engineering and machinery
TN Mining engineering. Metallurgy
Institution:University of Birmingham
ID Code:8252
This unpublished thesis/dissertation is copyright of the author and/or third parties.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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