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doi:10.3850/978-981-07-0319-6_227
Study on the Forming Process of Sheet Metal with High Aspect Ratio Holes
K. Y. Tu1, H. C. Chang1, H. T. Wang1, P. J. Chen1, T. J. Cheng1, F. K. Chen2 and Y. M. Chang2
1Metal Industries Research and Development Centre, No. 1001, Kaonan Highway, Kaohsiung, 81160, Taiwan, (R. O. C)
2Department of Mechanical Engineering, National Taiwan University, No. 1, Sec. 4, Roosevelt Rd., Taipei, 10617, Taiwan, (R. O. C)
ABSTRACT
Sheet metal forming is commonly used for mass production and is featured on the finished product with a smooth fracture surface. Numerous studies discussed about the forming process regarding the aspect ratio t/d (t: sheet thickness; d: punch diameter) less than 1. However few studies of forming process with aspect ratio more than 1 are discussed so far. With 1.0mm sheet thickness and 0.6mm hole diameter of SPCC, this research applies finite element analysis to conduct shear zone in the simulation of half-piercing, piercing, and shaving. The main parameters of die include punch diameter, die diameter, clearance, counterpunch force, and blankholder force respectively. Cockcroft & Latham (CL) and Normalized Cockcroft & Latham (NCL) criteria are used for ductile fracture prediction of shear zone. And, the simulation results are compared with experimental workpiece and then conclude NCL fracture criterion is the most feasible prediction for three stamping processes of sheet metal with high aspect ratio holes. Keywords: Sheet metal, Forming, High aspect ratio, Piercing, Shaving.
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