Simulation and Experimental Study of Corrugated Sheet Metal Stamping

Abstract

This paper concerned the stamping process of corrugated sheet metal for sealing device honeycomb manufacturing. GH536 foil with a thickness of 0.05mm was used to produce corrugated sheet metal with semi-hexagonal profile. Finite element models for the corrugated sheet metal stamping process were built to analyze the forces and material deformation. The prototype molds with a pair of pressure dies were designed and tested. Then according to the curling phenomenon occurred in the experimental result of prototype molds, the optimized final molds was designed with three pairs of pressure dies. The formed corrugated sheet metal by the final molds was much better. KEYWORD: Corrugated metal sheet; Stamping; Honeycomb manufacturing; Numerical simulation International Conference on Industrial Technology and Management Science (ITMS 2015) © 2015. The authors Published by Atlantis Press 1281 The demanded specifications of the corrugated sheet metal is shown in Figure 2, the angles between adjacent sides θ1=θ2 =120°, side length l1 = l2 = l3 = 0.8mm, thickness t=0.05mm. Figure 2. The demanded specifications of the corrugated sheet metal 2 NUMERICAL SIMULATION The principle of stamping is that the part with desired shape and size is obtained by a method of permanent plastic deformation of work piece. This process is achieved by the normal contact force and tangential frictional forces between the mold and the work piece. The stamping process involves three nonlinear problems in mechanics. (1) Geometric nonlinearity (Large displacement, rotation and deformation in the stamping process). (2) Physical nonlinearity (Also known as material nonlinearity which refers to elastic-plastic deformation of the material). (3) Boundary nonlinearity (Refer to non-linear relationship caused by contact friction between the die and work piece). The development of computer technology and finite element method provides a new way for complex engineering calculation. This paper used explicit dynamic software ANSYS\LS-DYNA to simulate the corrugated sheet metal stamping process 2.1 Original Design of Stamping Molds For the corrugated sheet metal stamping, special molds was designed as illustrated in Figure 3 and Figure 4. All the fillets are 0.1 mm. The material of the molds is P20 # steel. Since the GH536 foil is very thin, the deformation of molds is negligible in the forming process, so the molds can be regarded as rigid in simulation. The material properties of the molds are listed in Table 3. Figure 3. Illustration of upper die Figure 4. Illustration of lower die Table 3 The material properties of the molds Desinty (g/cm 3 ) Elastic Modulus (GPa) Possion’s ratio 7.8 206 0.3 The finite element model is illustrated in Figure 5. The molds were modeled using solid elements, and the foil was modeled using shell elements. The foil feed from the left with a preset motion, and the rigid molds moved in vertical direction. The foil and rigid molds were constrained to prevent undesired motion. Two stamping steps were simulated to form two semi-hexagonal profiles. The calculation time was set to 0.3s. The simulated stamping process is shown in Figure 6.