Experimental Verification of a Benchmark Forming Simulation

Landkammer, P., Loderer, A., Krebs, E., Sohngen, B., Steinmann, P. , Hausotte, T., Kersting, P., Biermann, D. and Willner, K. (2015) Experimental Verification of a Benchmark Forming Simulation. In: 16th International Conference on Sheet Metal, SheMet 2015, Erlangen-Nurnberg, Germany, 16-18 March 2015, ISBN 9783038354505 (doi: 10.4028/www.scientific.net/KEM.639.251)

Abstract

Forming of near-net-shaped and load-adapted functional components, as it is developed in the Transregional Collaborative Research Centre on Sheet-Bulk Metal Forming SFB/TR 73, causes different problems, which lead to non-optimal manufacturing results. For these high complex processes the prediction of forming effects can only be realized by simulations. A stamping process of pressing eight punches into a circular blank is chosen for the considered investigations. This reference process is designed to reflect the main aspects, which strongly affect the final outcome of forming processes. These are the orthotropic material behaviour, the optimal design of the initial blank and the influences of different contact and friction laws. The aim of this work is to verify the results of finite element computations for the proposed forming process by experiments. Evaluation methods are presented to detect the influence of the anisotropy and also to quantify the optimal blank design, which is determined by inverse form finding. The manufacturing accuracy of the die plate and the corresponding roughness data of the milled surface are analysed, whereas metrological investigations are required. This is accomplished by the help of advanced measurement techniques like a multi-sensor fringe projection system and a white light interferometer. Regarding the geometry of the punches, micromilling of the die plate is also a real challenge, especially due to the hardness of the high-speed steel ASP 2023 (approx. 63 HRC). The surface roughness of the workpiece before and after the forming process is evaluated to gain auxiliary data for enhancing the friction modelling and to characterise the contact behaviour.

• Item Type: Conference Proceedings
• Additional Information: Key Engineering Materials, volume 639, 2015, pages 251-258. Volume Editors: Micari F., et al.
• Status: Published
• Refereed: Yes
• Glasgow Author(s) Enlighten ID: Steinmann, Professor Paul
• Authors: Landkammer, P., Loderer, A., Krebs, E., Sohngen, B., Steinmann, P., Hausotte, T., Kersting, P., Biermann, D., and Willner, K.
• College/School: College of Science and Engineering > School of Engineering > Infrastructure and Environment
• Journal Name: Key Engineering Materials
• ISSN: 1013-9826
• ISBN: 9783038354505

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