Numerical analysis of the dependence of damage on friction during deep drawing of asymmetric geometries
The manufacturing of three-dimensional sheet metal components, such as car body parts, heavily relies on deep drawing. With the increasing demand for lightweight measures in the automotive industry due to CO2 limitation requirements, various methods are currently employed to reduce the weight of dee...
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| Format: | Article |
| Language: | English |
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Elsevier
2024-05-01
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| Series: | Advances in Industrial and Manufacturing Engineering |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2666912924000011 |
| _version_ | 1797352600168824832 |
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| author | Martina Müller Lars Uhlmann Tim Herrig Thomas Bergs |
| author_facet | Martina Müller Lars Uhlmann Tim Herrig Thomas Bergs |
| author_sort | Martina Müller |
| collection | DOAJ |
| description | The manufacturing of three-dimensional sheet metal components, such as car body parts, heavily relies on deep drawing. With the increasing demand for lightweight measures in the automotive industry due to CO2 limitation requirements, various methods are currently employed to reduce the weight of deep drawn components. However, these methods often overlook the potential for influencing the stress-strain dependent damage state within the component, even though it can greatly affect its performance in subsequent applications, and thus offers lightweight potentials. Friction between the deep drawing tools and the sheet metal is a key factor influencing the stress-strain state, and hence, represents a lever that can be utilized to manipulate the damage state in the component. This paper focuses on the numerical analysis of the dependence of damage on friction during deep drawing. Therefore, a rectangular geometry with an asymmetrical material flow is numerically investigated. A friction ratio is introduced with different constant friction coefficients for the corner of the tools and the straight sides. The established load paths at a chosen reference point are then considered in the form of selected stress and strain characteristics and the numerically predicted damage state is compared. The results are used to derive a recommended friction ratio that leads to less damage in the corner of the geometry. Afterwards strip drawing tool surfaces are modified to manipulate their friction properties using machine hammer peening. Subsequently, the influence of the structures of the strip drawing tool surfaces is quantified using strip drawing tests. The identified contact normal stress dependent friction coefficients are then implemented in the numerical simulation and the established numerical predicted damage state is examined to gain a more comprehensive understanding of how the friction ratio and the structure of the tool surfaces influence the damage state. |
| first_indexed | 2024-03-08T13:19:13Z |
| format | Article |
| id | doaj.art-03a77c7b6de645d0a23bb0f29490ee22 |
| institution | Directory Open Access Journal |
| issn | 2666-9129 |
| language | English |
| last_indexed | 2024-03-08T13:19:13Z |
| publishDate | 2024-05-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Advances in Industrial and Manufacturing Engineering |
| spelling | doaj.art-03a77c7b6de645d0a23bb0f29490ee222024-01-18T04:18:41ZengElsevierAdvances in Industrial and Manufacturing Engineering2666-91292024-05-018100136Numerical analysis of the dependence of damage on friction during deep drawing of asymmetric geometriesMartina Müller0Lars Uhlmann1Tim Herrig2Thomas Bergs3Manufacturing Technology Institute MTI of RWTH Aachen University, Campus-Boulevard 30, 52074, Aachen, Germany; Corresponding author.Manufacturing Technology Institute MTI of RWTH Aachen University, Campus-Boulevard 30, 52074, Aachen, GermanyManufacturing Technology Institute MTI of RWTH Aachen University, Campus-Boulevard 30, 52074, Aachen, GermanyManufacturing Technology Institute MTI of RWTH Aachen University, Campus-Boulevard 30, 52074, Aachen, Germany; Fraunhofer Institute for Production Technology IPT, Steinbachstr. 17, 52074, Aachen, GermanyThe manufacturing of three-dimensional sheet metal components, such as car body parts, heavily relies on deep drawing. With the increasing demand for lightweight measures in the automotive industry due to CO2 limitation requirements, various methods are currently employed to reduce the weight of deep drawn components. However, these methods often overlook the potential for influencing the stress-strain dependent damage state within the component, even though it can greatly affect its performance in subsequent applications, and thus offers lightweight potentials. Friction between the deep drawing tools and the sheet metal is a key factor influencing the stress-strain state, and hence, represents a lever that can be utilized to manipulate the damage state in the component. This paper focuses on the numerical analysis of the dependence of damage on friction during deep drawing. Therefore, a rectangular geometry with an asymmetrical material flow is numerically investigated. A friction ratio is introduced with different constant friction coefficients for the corner of the tools and the straight sides. The established load paths at a chosen reference point are then considered in the form of selected stress and strain characteristics and the numerically predicted damage state is compared. The results are used to derive a recommended friction ratio that leads to less damage in the corner of the geometry. Afterwards strip drawing tool surfaces are modified to manipulate their friction properties using machine hammer peening. Subsequently, the influence of the structures of the strip drawing tool surfaces is quantified using strip drawing tests. The identified contact normal stress dependent friction coefficients are then implemented in the numerical simulation and the established numerical predicted damage state is examined to gain a more comprehensive understanding of how the friction ratio and the structure of the tool surfaces influence the damage state.http://www.sciencedirect.com/science/article/pii/S2666912924000011DamageFrictionDeep drawingDual phase steel |
| spellingShingle | Martina Müller Lars Uhlmann Tim Herrig Thomas Bergs Numerical analysis of the dependence of damage on friction during deep drawing of asymmetric geometries Advances in Industrial and Manufacturing Engineering Damage Friction Deep drawing Dual phase steel |
| title | Numerical analysis of the dependence of damage on friction during deep drawing of asymmetric geometries |
| title_full | Numerical analysis of the dependence of damage on friction during deep drawing of asymmetric geometries |
| title_fullStr | Numerical analysis of the dependence of damage on friction during deep drawing of asymmetric geometries |
| title_full_unstemmed | Numerical analysis of the dependence of damage on friction during deep drawing of asymmetric geometries |
| title_short | Numerical analysis of the dependence of damage on friction during deep drawing of asymmetric geometries |
| title_sort | numerical analysis of the dependence of damage on friction during deep drawing of asymmetric geometries |
| topic | Damage Friction Deep drawing Dual phase steel |
| url | http://www.sciencedirect.com/science/article/pii/S2666912924000011 |
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