Simulation and numerical analysis of warm stamping (AA6061)

Abstract

Abstract Stamping process is an important sheet metal forming process used in domestic and automotive components. In this process, blank material is converted into the desired complicated shape by punching process.Stamping includes a process such as punching using a punch or ram, blanking, embossing, bending, flanging, and coining.Cost minimisation ,less time consumption, increase in efficiency are very important in the recent manufacturing industry. Today simulation techniques are used to analyse the performing of dies, processes and billets prior to real timeimplementation. Simulations enable us to find out the common defects such as tears, wrinkles, and material thinning. Finite element analysis (FEA) is the method of simulating the process of sheet metal forming to determine various behaviour of the sheet metal and helps us to find out whether it will produce parts free of defects such as fracture or wrinkling. Sheet metal forming is a popularly used metal working process. In this paper stamping process is analysed numerically using a simulation software package LSTC – LSDYNA. A three dimensional thermo-mechanically coupled stamping model is analysed and its validations are presented. The analysis data from the numerical simulation helps in understanding the real-time mechanism of sheet metal forming process.There areonly few works were reported on numerical analysis of warm stamping of AA6061 such as load requirement, blank holder pressure, stress-strain analysis.This work is based on study the deformation behaviour of sheet metal, flow stress analysis, contact pressure and punch velocity.