A New Process Optimization Of Deep Drawing Part For Sheet Metal Forming In Automotive Industry

Year 2022, Volume: 25 Issue: 2, 879 - 885, 01.06.2022

Mehmet Mısırlı Aysun Ayday

https://doi.org/10.2339/politeknik.911780

Abstract

Drawing die complexity is higher than conventional stamping operations, nowadays. It needs to decrease stamping die operation numbers for a part to reduce project budget consumption. Therefore, frequency of tearing, thinning, crack occurrence increase while this amendment. Force, blank cutting, blank location on the drawing die and process optimization were investigated to decrease tearing, thinning and crack occurrence in Transit bodyside inner panels which have over 110 mm. deep drawing process. Formability was improved at the end of this study. Thus production scrap, stoppage time of stamping line were decreased over 90%. This study was conducted at Ford Otosan.

Keywords

Deep drawing, Sheet metal forming, Drawing die, Stamping dies process optimization, press

Project Number

Yok

Otomotiv Endüstrisinde Kullanılan Derin Çekme Kalıplarında Yeni Bir Optimizasyon Yaklaşımı

Abstract

Günümüzde otomotiv sektöründeki proje maliyetlerinin günden güne azalarak, karlılığın artması beklenmektedir. Sac şekillendirme süreçlerinde de bu doğrultuda ilerleyerek, daha karmaşık parçaları daha az operasyonda tamamlanması hedeflenmektedir. Bir operasyonda gerçekleştirilen karmaşıklığın artması, plastik şekil verme süreçlerinde daha fazla yırtık, incelme, çatlak problemleri ile karşılaşılmasına neden olmaktadır. Bu çalışmada karmaşık yapılardaki derin çekme parçalarında kuvvet, açınım boşaltmaları, açınım konumlaması gibi optimizasyonlarla yırtık, incelme, çatlak problemlerinin azaltılması amaçlanmıştır. Çalışma sonunda şekillendirme kabiliyetinin arttığı görülmüştür. Bu sayede de imalat süreçlerindeki hurda, hat duruş zamanı %90 oranında azaltılmıştır. Bu çalışma Ford Otosan çatısı altında yürütülmüştür.

Keywords

Sac şekillendirme, , Çekme kalıbı, Pres kalıpları optimizasyonu

Supporting Institution

Yok

Project Number

Yok

Thanks

Bu çalışmadan Ford Otosan Grubuna teşekkürü bir borç biliriz.

References

• [1] Wang L., An XY., Zhu B., Wang YL., Zhang YS., Research on Intelligent Process and Production Method of Hot Stamping, The 3rd. International Conference on Advantage High Strength Steel and Press Hardening (2017).
• [2] Kuhnert F., Stürmer C., Five trends transforming the Automotive Industry. Publishing PWC Turkey, (2020).
• [3] Giampieri A., Ling-Chin J., Ma Z., Smallbone A., Roskilly AP., A review of the current automotive manufacturing practice from an energy perspective. Applied. Energy, (2020).
• [4] Henriksson F., Introducing New Materials in the Automotive Industry, Linköping University, Sweden, (2017).
• [5] Badguyar TY., Wani VP., Optimization of stamping process parameters for material thinning with design of experiment approach. IVth. International Conference on Production and Industrial Engineering, (2016).
• [6] Rai PK., Mohammad A., Jafri HZ., Causes & Preventation of Defects (Burr) In Sheet Metal Component. Int. J. Eng. Res. Appl. (2013).
• [7] Feistle M., Koslow I., Krinninger M., Golle R., Volk W., Reduction of burr formation for conventional shear cutting of boron-alloyed sheets through focused heat treatment. The 50.th CIRP Conference on Manufacturing Systems, (2017).
• [8] Özdilli Ö, Erdin M, Comparison of common deep drawing steel Sheets in terms of blank holder force and friction conditions. International Journal of Automotive Science and Technology (2018).
• [9] Zoesch A, Wiener T, Kuhl M, Zero defect manufacturing: Detection of cracks and Thinning of material during deep drawing processes. 9th CIRP Conference on Intelligent Computation in Manufacturing Engineering (2012).
• [10] Kakandikar GM., Nandedkar VM., Prediction and optimization of thinning in automotive sealing cover using genetic algorithm. Journal of Computational Design and Engineering 3 (2016).
• [11] Firat M., A numerical analysis of sheet metal formability for automotive stamping applications Computational Materials Science (2008).
• [12] Neto DM., Oliveira MC., Santos AD., Alves JL., Menezes LF., Influence of boundary conditions on the prediction of springback and wrinkling in sheet metal forming. International Journal of Mechanical Sciences (2017).
• [13] Boljanovic V., Sheet Metal Forming Process And Die Design, Industrial Press Book, New York, (2004).
• [14] Golovashchenko SF., A study on trimming of aluminum autobody sheet and development of a new robust process eliminating burrs and slivers. International Journal of Mechanical Sciences (2006).
• [15] Sousa R., Incremental Sheet Forming Technologies. Material Science and Enginering, (2016).