Session: 02-07-01: Advanced Material Forming, Friction Stir Welding, and Deformation

Paper Number: 70171

Start Time: Thursday, 01:20 PM

70171 - A Numerical Study on Springback of a Channel Through the Oscillation of Punch 

The current demand in automotive vehicle usage results in sudden increases in fuel consumption, increasing air pollution. To avoid the environmental regulation penalty, the vehicle industry researches innovation, reduces vehicle weight, and decreases fuel consumption. However, the innovation related to light-weighting is not only an option anymore but became a mandatory necessity to decrease fuel consumption. To achieve this target, the industry has been looking at fabricating components from high strength to ultra-high strength steels or lightweight materials. With the usage of advanced high strength steels, the lightweight was achieved by reducing a gage thickness without compromising the strength aspect. However, due to their high strength property often challenges occurred are higher machine tonnage requirement, sudden fracture, geometric defect, etc. The geometric defect comes from the elastic recovery of a material, which is also known as a springback. Springback is commonly known as a manufacturing defect due to the geometric error in the part, which would not be able to fit in the assembly without secondary operation or compensation in the forming process. It is learned that the springback of the material increases with an increase in the material strength and/or decrease in material thickness. In advanced high strength steels, higher strength and lower gage thickness options make the part prone to higher springback. Due to these many challenges with the materials and their properties which affect the springback, other research routes involved are innovative forming processes which would reduce the springback such as applying electricity through the material after forming and before the release of the load, performing warm or hot forming, die compensation, etc. One such innovative process which is studied in the paper is oscillation of the punch during the forming process. In this paper, the 2D channel strip of the aluminum 2024 high strength alloy will be used in the bending process. The process of bending with punch die and the blank will be model in the ABAQUS finite element software. First, the conventional channel deformation will be performed and the deformation will be studied and springback will be compared with the desired shape. Then the oscillation of the punch will be set either in the lateral or longitudinal direction. The frequency of the punch will also be changed to see the effect on the deformation behavior of the material and springback after the punch release. The force required during the process will be studied and compared. Further the maximum stress, deformation of the channel and springback will be analyzed and presented.

Presenting Author: Tanya Buddi Gokaraju Rangaraju Institute of Engineering and Technology

Authors:

Chetan P. Nikhare Penn State Erie - Behrend College
Tanya Buddi Gokaraju Rangaraju Insutitute of Engineering and Technology
Nitin Ramesh Kotkunde Birla Institute of Technology & Science
Swadesh Kumar Singh Gokaraju Rangaraju Institute of Engineering and Technology