Investigation of Contact Conditions During Stamping of a Thin Plate
Stamping is one of the most used manufacturing processes, in which a product is formed with the help of dies and workpiece. Servo press used for stamping operations are characterized with high speed, which leads to higher production rate. Due to high speed, real time monitoring of the stamping process is quite a difficult job because of lack of appropriate sensing technology, which may lead to deterioration of accuracy of the products. The defects arise in the products are mainly due to gaps that exist in between die and workpiece. The common defects to be found are tearing, wrinkling, springback, earing, etc. The stamping operation have been monitored in recent years, yet the monitoring has not improved to detect defects effectively.
The present work proposes a methodology for wave propagation through solids which can be used to detect gaps between die and workpiece during stamping operation. In the present work, the contact condition between die and workpiece in terms of contact pressure is studied. The contact between die and workpiece should be perfect to avoid any defects. A method is developed for modelling of elastic waves propagation in solids to measure contact conditions between die and workpiece during stamping. A two-dimensional model is developed for the study which further reduces the wave propagation equations to two-dimensional equations. A finite difference time domain (FDTD) method has been employed, in which a central finite difference scheme is used to approximate the derivatives involved in the elastic wave equations. The geometric model is discretized in space and time. The numerical stability of the wave propagation model is achieved through courant stability condition, i.e., Courant-Friedriches-Lewy (CFL) number. Material properties like density and acoustic impedance of the material are defined and allocated to each cell in the grid space.
Two cases, i.e., flat die-workpiece interface and inclined die-workpiece interface, are investigated in the present work. The elastic wave propagation is simulated in the 2D model of the die and workpiece using reflecting boundary conditions. The wave propagation model is tested and validated using courant stability condition. The amplitudes of reflected and transmitted waves are compared to study the reflected wave energy and transmitted wave energy inside die and workpiece. Further, the experimental and simulation-based results of reflected and transmitted wave characteristics are compared for different materials in terms of reflected and transmitted wave height ratio and, material properties such as acoustic impedance. It is found that the numerical simulation results are in good agreement with the experimental results. This helps in examining the contact conditions between the die and workpiece in terms of output parameters like, acoustic impedance, transmitted wave energy and, reflected wave energy.
Investigation of Contact Conditions During Stamping of a Thin Plate
Category
Technical Paper Publication
Description
Session: 02-09-01 Computational Modeling and Simulation for Advanced Manufacturing I
ASME Paper Number: IMECE2020-24547
Session Start Time: November 17, 2020, 04:00 PM
Presenting Author: PUNEET TANDON
Presenting Author Bio: Prof. Puneet Tandon is a joint Professor of Mechanical Engineering and Design at PDPM Indian Institute of Information Technology, Design and Manufacturing, Jabalpur, India. Presently, he is serving as the Head of Mechanical Engineering at the Institute. He is the mentor of the deLOGIC Lab (http://delogic.iiitdmj.ac.in), and Soln Lab (http://soln.iiitdmj.ac.in). His primary research interests include CAx technologies, including CAD/CAM/CAE, BioCAD, and Human Factors in CAD; Innovative Product Design; and Advanced Manufacturing Technologies, including Hybrid, Dieless, Additive, and Smart Manufacturing.
The works of his research group in the field of innovative design and advanced manufacturing techniques are internationally recognized. He graduated in Mechanical Engineering from the National Institute of Technology Kurukshetra, India, and received Master and Doctoral degrees in Mechanical Engineering from the Indian Institute of Technology Kanpur, India.
Prof. Puneet Tandon has more than 32 years of experience in engineering research and education. He has more than 250 publications in peer-reviewed journals/book chapters/conference proceedings, besides being the author of 2 books and several patents. He has been editor/guest editor of a few Journals. Fifteen doctoral students have been awarded degrees under his supervision.
Prof. Tandon has been awarded the 2020 DUO-India Fellowship Award with Padova University, Italy. He has been awarded various international projects under DST-RFBR and DST-JSPS schemes. Besides, he had executed projects funded by multiple funding agencies and organizations. He has been the Coordinator of two GIAN courses, sponsored by MHRD, Govt. of India.
He was also organizer of the International Conference on Innovations in Design and Manufacturing (InnDeM) 2012 and Design Workshops (DeW) during the years 2010, 2013, 2014, and 2016, an international event organized in collaboration with Ministry of Foreign Affairs (MOFA), Japan. He is a member of the International Programme Committee of CAD Conferences and on advisory committees of various international conferences. He has been a part of multiple Conferences Programme Committees and Technical Committees. Besides, he has chaired numerous sessions in international and national conferences of repute. He has also delivered a lot of Keynote lectures, Plenary Addresses, and Invited Talks. He also participates actively in international academic organizations.
Authors: Harshal Shahare PDPM Indian Institute of Information Technology, Design and Manufacturing, Jabalpur
Rohan Rajput PDPM Indian Institute of Information Technology, Design and Manufacturing, Jabalpur
Puneet Tandon PDPM Indian Institute of Information Technology, Design and Manufacturing, Jabalpur