Rapid Freeform Sheet Metal Forming: Technology Development and ...
Rapid tools in sheet metal forming processes
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Doctoral Programme in Mechanical Engineering Rapid tools in sheet metal forming processes Doctoral Thesis of Lorenzo Iorio – Supervisor: Prof. Matteo Strano XXX Cycle, Manufacturing and Production Systems Objectives Results References Mecc PhD Doctoral Programme in Mechanical Engineering Programme Coordinator prof. Daniele Rocchi Department of Mechanical Engineering Via La Masa 1 20156 Milano info and contact [email protected] Phd ConclusIons Introducti on Analysis of Traditional stamping tools solutions Evaluation of materials to be used as an efficient alternative Investigation of new solution Application of rapid tools setup in 3 sheet metal forming processes Experimental analysis Economical comparison Process simulation Development of new solutions: Compensation algorithm (Stamping) Redesigned solutions (Air bending) Prototypal proposal (Rotary draw bending) FEM models Strain maps comparison Fracture analysis Compensation results The FEM model is robust in simulating stamping, air bending and rotary draw bending processes The compensation algorithm is robust also for complex geometries Fatigue tests have been performed, whose results suggest that the tools can be used in medium production batches The rapid tools developed for air-bending process have similar performances with respect to commercial solutions (metal and nylon tools) in terms of bend angle and standard deviation of the process The rotary draw bending case demonstrates that is not trivial to design a rapid tools setup, because some involuntary complications can be introduced in the process with the consequent increase of the tools costs (i.e. pressurized rubber plug) Analysis of geometrical deviations Stress Analysis 1. IORIO, Lorenzo; STRANO, Matteo; MONNO, Michele. Development of a Die Compensation Algorithm for Sheet Metal Stamping With Deformable Tools. In: ASME 2015 International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2015. p. V001T02A089- V001T02A089. 2. IORIO, Lorenzo; STRANO, Matteo; MONNO, Michele. Rapid Tools Compensation in Sheet Metal Stamping Process. In: MATEC Web of Conferences. EDP Sciences, 2016. p. 10009. 3. Iorio, Lorenzo, et al. "Design of Deformable Tools for Sheet Metal Forming." Journal of Manufacturing Science and Engineering 138.9 (2016): 094701.
Transcript of Rapid tools in sheet metal forming processes
Doctoral Programme in Mechanical Engineering
Rapid tools in sheet metal forming processes
Doctoral Thesis of Lorenzo Iorio – Supervisor: Prof. Matteo Strano XXX Cycle, Manufacturing and Production Systems
Objectives
Results
References
MeccPhD
Doctoral Programme in Mechanical Engineering
Programme Coordinator prof. Daniele Rocchi
Department of Mechanical Engineering
Via La Masa 1
20156 Milano
info and contact
Phd
Co
nclu
sIo
ns
Intr
od
ucti
on
Analysis of Traditional stamping tools solutions
Evaluation of materials to be used as an efficient alternative
Investigation of new solution
Application of rapid tools setup in 3 sheet metal forming processes
Experimental analysis Economical comparison Process simulation Development of new solutions: Compensation algorithm (Stamping) Redesigned solutions (Air bending) Prototypal proposal (Rotary draw bending)
FEM models
Strain maps comparison
Fracture analysis
Compensation results
The FEM model is robust in simulating stamping, air bending and rotary drawbending processes
The compensation algorithm is robust also for complex geometries Fatigue tests have been performed, whose results suggest that the tools can be
used in medium production batches The rapid tools developed for air-bending process have similar performances with
respect to commercial solutions (metal and nylon tools) in terms of bend angle andstandard deviation of the process
The rotary draw bending case demonstrates that is not trivial to design a rapid toolssetup, because some involuntary complications can be introduced in the processwith the consequent increase of the tools costs (i.e. pressurized rubber plug)
Analysis of geometrical deviations
Stress Analysis
1. IORIO, Lorenzo; STRANO, Matteo; MONNO,Michele. Development of a Die CompensationAlgorithm for Sheet Metal Stamping WithDeformable Tools. In: ASME 2015 InternationalManufacturing Science and EngineeringConference. American Society of MechanicalEngineers, 2015. p. V001T02A089-V001T02A089.
2. IORIO, Lorenzo; STRANO, Matteo; MONNO,Michele. Rapid Tools Compensation in SheetMetal Stamping Process. In: MATEC Web ofConferences. EDP Sciences, 2016. p. 10009.
3. Iorio, Lorenzo, et al. "Design of DeformableTools for Sheet Metal Forming." Journal ofManufacturing Science and Engineering 138.9(2016): 094701.
