Finite element modelling of multi-point forming

Abosaf, Mohamed (2018). Finite element modelling of multi-point forming. University of Birmingham. Ph.D.

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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: Thesis (Doctorates > Ph.D.)
Award Type: Doctorates > Ph.D.
College/Faculty: Colleges (2008 onwards) > College of Engineering & Physical Sciences
School or Department: School of Engineering, Department of Mechanical Engineering
Funders: None/not applicable
Subjects: T Technology > TJ Mechanical engineering and machinery


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