Ultrasonically assisted deep drawing process: Two-stage finite element analysis and experimental verification

Öz

In this study, Ultrasonically Assisted Deep Drawing Process was developed in order to improve formability of sheet metals in Conventional Deep Drawing Process. Effects of ultrasonic vibrations, applied onto the blank holder in axial direction, on formability of sheet metal were investigated numerically by finite element analyses, and the results of such analyses were verified by deep drawing experiments. In the numerical study, a methodology for two-stage finite element analyses including transient structural and forming analysis was developed. In conventional and ultrasonically assisted deep drawing analyses, limiting drawing ratios and maximum drawable cup depths for DC01 and DC04 materials prone to certain process parameters were compared. With application of ultrasonic vibrations, an increase of up to 9% in limiting drawing ratio and up to 26% in cup depth were achieved. In the analyses performed on circular materials of identical diameters, it was determined that the thinning on sheet metal decreased by up to 43%. As result of the validation experiments, increase in limiting drawing ratio and cup depth was achieved as 11% and 31%, respectively. Numerical results were found to be in good agreement with experimental results since dynamic impact, stress superposition and contact separation effects of ultrasonic vibrations could be effectively modeled in finite element analyses with the proposed method. Small differences in obtained results may be due to the reason that it was not possible to involve the effects of acoustic softening and friction coefficient reduction on the material in numerical analyses.

Anahtar Kelimeler

• Deep Drawing Process
• Ultrasonic Vibrations
• Limiting Drawing Ratio
• Finite Element Analyses

Ultrasonik destekli derin çekme işlemi: İki aşamalı sonlu elemanlar analizi ve deneysel doğrulaması

Öz

Bu çalışmada, Geleneksel Derin Çekme Yöntemi'nde sac metal malzemelerin şekillendirilebilirliğini iyileştirebilmek adına Ultrasonik Destekli Derin Çekme Yöntemi geliştirilmiştir. Derin çekme işleminde baskı plakasına eksenel yönde uygulanan ultrasonik titreşimlerin malzemenin şekillendirilebilirliğine etkileri sonlu elemanlar analizleriyle nümerik olarak araştırılmış, elde edilen sonuçlar derin çekme deneyleriyle doğrulanmıştır. Nümerik çalışmada, zamana bağlı yapısal ve şekillendirme analizlerini içeren iki aşamalı sonlu elemanlar analizini içeren metodoloji geliştirilmiştir. Geleneksel ve ultrasonik destekli derin çekme analizlerinde, belirli işlem parametrelerine maruz kalan DC01 ve DC04 malzemelerin sınır çekme oranları ve maksimum çekilebilir kupa derinlikleri kıyaslanmıştır. Ultrasonik titreşimlerin etkisiyle sınır çekme oranında %9’a, kupa derinliğinde ise %26’ya varan artış sağlanmıştır. Aynı çapa sahip dairesel malzemeler üzerinde gerçekleştirilen analizlerde, sac malzemedeki incelmenin %43’e varan oranda azaldığı tespit edilmiştir. Doğrulama deneyleri neticesinde sınır çekme oranında ve kupa derinliğindeki artış oranları ise sırasıyla %11 ve %31 olarak gerçekleşmiştir. Ultrasonik titreşimlerin dinamik darbe, gerilme süperpozisyonu ve temas ayrılması etkileri, önerilen yöntemle sonlu elemanlar analizlerinde etkin bir şekilde modellenebildiğinden nümerik analiz sonuçlarının deneysel sonuçlarla iyi bir uyum içinde olduğu görülmüştür. Buradaki küçük farkların, ultrasonik titreşimlerin malzeme üzerindeki akustik yumuşatma ve sürtünme katsayısını azaltma etkilerinin nümerik modele aktarılamamasından kaynaklandığı düşünülmektedir.

Anahtar Kelimeler

• Derin Çekme İşlemi
• Ultrasonik Titreşimler
• Sınır Çekme Oranı
• Sonlu Elemanlar Analizleri

Kaynakça

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