Analysis of Blank-Die Contact Interaction in Pulsed Forming Processes

Abstract

During recent decade, significant efforts were dedicated to increasing the amount of Aluminum Alloys in automotive parts in order to reduce the net weight of cars. Processes of pulsed forming are known to expand the capabilities of traditional stamping operations. Propagation of pulsed electromagnetic field can be defined by quasi-stationary Maxwell equations, solved numerically using a non-orthogonal Lagrangian mesh. Suggested formulation included modelling of contact interaction of the blank with deformable die. Mild contact model based on introduction of acting-in-vicinity forces repelling the surfaces to be in contact was employed. It was tested by analyzing the elastic impact of bars and then was applied to the corner filling operation. This operation was analysed as a single pulse and as a multi pulse forming process. It indicated that some compromise between the blank formability enhancement and level of contact stresses on the die surface can be found. In addition, some examples of tubular parts pulsed press fitting using tube expansion with pulsed pressure were analyzed. Specific attention was paid to the analysis of factors playing important role in residual contact pressure between the exterior and interior tubes in pulsed press fitting operation.