FLD Creation For SS304 Using Experiments & Computer Simulations and To Study Effects of Various Parameters on it

Abstract

Sheet metal forming is the process of converting a at sheet of metal into a part of desired shape without fracture or excessive localized thinning. In sheet metal forming it is necessary to know that when the material gets failed while shaping it to desire dimensions. Forming Limit Diagram is used during the design stage of any new sheet metal component. It gives transparency and better idea for tooling shape and for optimizing process variables. It is nothing but a combination of critical surface limit strain under di erent condition. In this study, the uniaxial testing of SS304 specimens had been performed using dif- ferent samples according to direction of rolling (0,45 & 90 degrees) to evaluate the material properties usually yield strength, ultimate tensile strength, strain hardening exponent, anisotropy, etc. First of all FLD was obtained experimentally using hemi- spherical dome test. The tool setup for this test had been designed & manufactured according to ASTM E2218. The properties obtained from uniaxial tensile testing were employed to be used by software for computer simulation & determination of FLD. A typical industrial component had been chosen for computer simulation of FLD. Further the validation of computer results with experimental results were done. Computer simulation are in excellent agreement with experimental results. Moreover the e ect of various parameters were examined such are lubrication, blank holding pressure, work hardening exponent, punch velocity, sheet thickness etc on FLD and Conclusions have been drawn. This study will help to design & optimize process variables for new product develop- ment. That reduces lead time & cost also improves quality & productivity.