Simulation and Experimental Approach for Metal Forming with a Multi-Point Die

Abstract

Multi-point forming (MPF) is considered a flexible and innovative sheet metal forming process that allows for the creation of three-dimensional curved surfaces. This study investigates the effects of various parameters on the final product in metal forming using a multi-point die. The research employs a combination of numerical simulations and experimental work to analyze and minimize defects in the forming process. The concentration is on brass (Cu Zn 65-35) and rubber materials, with specific thicknesses of 0.71 mm and 2 mm, respectively. Although ANSYS 15.0 is used to study the stresses and strains resulting from the formation process with the multi-point die (MPD), the experimental work was conducted to study the effect of two parameters: forming speeds (5 and 15 mm/min) and holding times (1, 3, and 5 minutes were used in this process). The simulation results reveal that the use of rubber significantly reduces defects such as dimples on the sheet surface. Additionally, the presence of rubber helps distribute the force, leading to a reduction in maximum stress and strain in the blank profile to approximately 27% and 49%, respectively, in the second case. The study also explores the impact of forming speed and holding time on spring back. BY measuring the dimensional accuracy of the final products. A forming speed of 5 mm/min and a holding time of 5 minutes resulted in the best outcomes, with a minimum average spring back (0.997). Moreover, the ANOVA algorithm was used to discuss the results which indicated that the forming speed and holding time significantly affect the dimensional accuracy. The research shows that altering settings and adding rubber to multi-point forming improves product quality and accuracy. This study enhances metal forming knowledge and improves industrial processes.