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Title: Finite Element Studies and Experimental Validation of Asymmetric Incremental Sheet Forming of Extra Deep Drawing Steel
Researcher: KURRA SURESH
Keywords: Finite Element, Sheet Forming, Drawing Steel
University: Birla Institute of Technology and Science
Completed Date: 
Abstract: Incremental sheet forming (ISF) process has been identified as a potential and economically viable process for sheet metal prototypes and low volume production. The process is very flexible and can be carried out on a computer numerical control (CNC) milling machine, robots or specially designed machines for ISF applications. In this process, a flat sheet is held in a simple fixture and is deformed into required shape by a spherical-ended tool. The path of the tool is controlled by a part program generated using computer aided manufacturing (CAM) software. The main attractive features of this process are simple tooling, and better forming characteristics than the conventional sheet metal forming processes. The process can be carried out without any die or with a partial die setup, made up of low cost material, such as plastic or wood. The process has been demonstrated as a potential process for forming complex shapes, automotive service panels, head light casing and customized bio-medical parts, such as, ankle support, plate prosthesis, implants for arthroplasty, cranial implants etc. newlineRealizing the potential advantages of ISF process, the present thesis focused to investigate the behavior of Extra Deep Drawing (EDD) steel in ISF process. This material is widely used in automotive applications. The formability of EDD steel in terms of maximum formable wall angle has been evaluated using Varying wall Angle Conical Frustums (VWACF) and Varying Wall Angle Pyramidal Frustums (VEAPF). These geometries can minimize the number of experiments required for formability analysis as compared to constant wall angle conical and pyramidal frustums. The formability of the parts has also been evaluated using analytical forming limit curve and finite element simulations. The effect of process parameters on formability has been studied through systematic experiments. newlineThe state of stresses and strains in incremental forming of VWACF and VWAPF parts have been studied through finite element simulations. The thickness distribution of th
Pagination: 6.76 MB
Appears in Departments:Mechanical Engineering

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