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Modeling and numerical analysis of the process of punching aluminum sheets taking into account punch wear

Bohdal Łukasz, Kośka Katarzyna, Miksza Mateusz, Patyk Radosław, Kalata Franciszek

Journal of Mechanical and Energy Engineering

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2022

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Vol. 6, No 1

13--20

EN

The paper presents a modeling and analysis algorithm as well as the results of simulation tests with the use of FEM of a process of punching aluminum sheets used for casings. In industrial practice, the difficulty lies in the correct selection of punching clearance. In order to predict the effect of clearance on the quality of the edge cut, a numerical model was developed taking into account the geometric and physical nonlinearity with damage. The model makes it possible to simulate all the phases of the cutting process, including the fracture phase, which is of key importance to the formation of the workpiece edge. A new approach of creating a real geometry of the punch edge was presented. The geometries developed take into account the most common defects of the punch cut edges. Owing to this, it is possible to predict the course of the proces depending on the type and degree of the wear of the cutting edges of the punch. The results obtained showed that for clearances below the value of a = 0.16 mm, the crack has the shape of a straight line. Clearance values a = 0.16 mm and below allow one to obtain a perpendicular shear area and a considerable width of the smooth cutting zone. As the clearance increases, the width of the cutting zone decreases. Punch wear significantly reduces the smooth zone and it increases perpendicular deviation of cut surface.

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Badania symulacyjne i eksperymentalne procesu wykrawania części z blach aluminiowych o zmiennej grubości

Bohdal Łukasz, Kalata Franciszek, Kałduński Paweł, Kukiełka Leon, Patyk Radosław, Kukiełka Krzysztof

Autobusy : technika, eksploatacja, systemy transportowe

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2019

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R. 20, nr 9

52--56

PL

W artykule przedstawiono algorytm modelowania i analizy oraz wyniki badań symulacyjnych z zastosowaniem MES oraz eksperymentalnych procesu wykrawania części z blach aluminiowych stosowanych w przemyśle motoryzacyjnym do budowy pojazdów. Uzyskuje się zarówno oszczędność energii oraz obniżenie masy samochodów. Analiza dotyczy wpływu warunków procesu wykrawania na jakość ciętej krawędzi wyrobu. Symulacje komputerowe przeprowadzono dla przestrzennych stanów naprężeń i płaskich stanów odkształceń z wykorzystaniem Solvera LS-DYNA oraz aplikacji LS-PrePost. Otrzymano mapy intensywności naprężeń i odkształceń dla dowolnej chwili czasowej z uwzględnieniem nieliniowości występujących w procesie wykrawania. Badania symulacyjne przeprowadzono dla różnych grubości blach oraz zmiennych wartości luzu miedzy stemplem a matrycą. Wyniki symulacji zweryfikowano eksperymentalnie. Opracowane aplikacje numeryczne oraz otrzymane wyniki badań mogą być wykorzystane do projektowania i optymalizacji procesu wykrawania.

EN

The paper presents the modeling and experimental researches of the blanking process of parts from aluminum sheets used in automotive industry to building vehicles. Analysis concerns influence of process conditions on quality of cut edge. Numerical analysis was performed for the spatial states of stresses and flat states of strains in LS-DYNA solver and LS-PrePost application regarding blanking process nonlinearities. Researches were realized for different sheet’s thickness and punch-die clearances. Results were verified experimentally. Obtained maps of stresses, strains, displacement at any moment of time can be used for design of the blanking process and it’s optimization.

3

Assessment of Aluminum FSW Joints Using Ultrasonic Testing

Adamus K., Lacki P.

Archives of Metallurgy and Materials

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2017

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Vol. 62, iss. 4

2399--2404

EN

The paper concerns aluminum joints made using friction stir welding. Although in the aerospace industry there is a tendency to replace metal components with composites, aluminum continues to be a valuable material. Its share in the aircraft structures is the biggest among all structural metals. Lots of aluminum components are made of sheets and most of them require joining. Friction stir welding is a relatively new joining technology, particularly with regard to the sheets having a thickness of 1 mm or lower. The paper is dedicated to non-destructive testing of such joints using ultrasonic inspection. It was found that ultrasonic testing allows for distinguishing between joints without material discontinuities, joint with material discontinuities at the advancing side and joint with discontinuities extending through the whole width of the stir zone. During research only horizontally aligned defects were taken into account.