Abstract
This study, with experiments and comparisons, aims to analyze the difference of stainless (SUS316L) microtubes in the flaring forming among dies with various semicone angles (35°, 40°, 45°, 50°, and 55°). The flow rule by Prandtl-Reuss combined with the finite element deformation theory and updated Lagrangian formulation (ULF) is applied to establish the finite element analysis equation for an incremental elastoplastic deformation to simulate the microtube flaring process. The broadrminalgorithm is utilized in the forming process for the elastoplastic state and die contact. The simulation data allow acquiring the deformation traceability, the relationship between punch load and punch stroke, the distribution of stress and strain, the distribution of the thinnest thickness resulted from dies with different semicone angles, and the distribution of flaring radius caused by dies with distinct semicone angles in the forming process. The experimental result presents similar results to the relationship between punch load and punch stroke and the simulation of the coefficient of frictionμ=0.05, revealing the analysis being suitable for the analysis of microtube cone angle flaring process. The analysis and experimental results show that the thinnest thickness of the microtube increases with increasing semicone angles of dies and the maximal flaring radius of microtubes increases with increasing semicone angles of dies.
Highlights
The rapid development of modern industries has accelerated the progress of material processing, in which stamping technique that could largely enhance manufacturing accuracy and production efficiency cannot be neglected
The results are compared with the stroke-punch load relationship acquired in the experiment and the relationship is close to the experiment curve when the coefficient of friction μ = 0.05
Elastoplastic deformation finite element analysis is utilized for the calculation in this study, and selective reduced
Summary
The rapid development of modern industries has accelerated the progress of material processing, in which stamping technique that could largely enhance manufacturing accuracy and production efficiency cannot be neglected. Almeida et al [5] designed dies with different cone angles for the experiments of necking and flaring, compared the results with finite element analysis, and changed the coefficient of friction to achieve the best forming and reduce the product wrinkling. The stroke is set a fixed value in the simulation process, and punch load, deformation traceability, stress figure, strain figure, and forming thickness distribution are further discussed and calculated the strength with numerical simulation to shorten the developing time. It aims to achieve the optimization of cost reduction and product quality enhancement. ⟨E⟩ VE (4) + ∑ ∫ [E]T [Z] [E] dV and K is generally regarded as the overall elastoplastic stiffness matrix, {Δu} the nodal displacement increment, {ΔF} the nodal force increment, [Q] and [Z] the stress modified matrix, and [Cep] the elastoplastic stress-strain matrix
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