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1st Progress Report - Mert Karakaş

This 1st progress report summarizes a finite element analysis of deep drawing process performed in ABAQUS. An assembly was created with rigid die, holder and punch interacting with a deformable blank material. Elastic material properties were defined for the blank and a dynamic explicit simulation was run up to 0.1 seconds with the punch moving at 20 mm/s. Results showed maximum von Mises stress of 98.4 MPa in the blank, below the yield strength, indicating elastic behavior only. Maximum blank displacement was 0.3 mm. Further reports will examine plastic deformation behavior.

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43 views5 pages

1st Progress Report - Mert Karakaş

This 1st progress report summarizes a finite element analysis of deep drawing process performed in ABAQUS. An assembly was created with rigid die, holder and punch interacting with a deformable blank material. Elastic material properties were defined for the blank and a dynamic explicit simulation was run up to 0.1 seconds with the punch moving at 20 mm/s. Results showed maximum von Mises stress of 98.4 MPa in the blank, below the yield strength, indicating elastic behavior only. Maximum blank displacement was 0.3 mm. Further reports will examine plastic deformation behavior.

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MIDDLE EAST TECHNICAL UNIVERSITY

DEPARTMENT OF MECHANICAL ENGINEERING

ME 541
PLASTICITY AND COMPUTER AIDED METAL FORMING
SPRING 2019-2020

TERM PROJECT
1st PROGRESS REPORT

MERT KARAKAŞ
2033728
18/04/2020
INTRODUCTION
In the term project the deep drawing process is simulated by using finite element method. Deep
drawing is a sheet metal forming process in which a sheet metal blank is drawn into a forming die by
the mechanical action of a punch. ABAQUS software is used for finite element analysis.

In the term project, deep drawing process will be examined with three kinds of hardening models,
two kinds of yielding functions. Furthermore various parameters will be used and effects will be
explored. For the 1st progress report a solid model is created and a simulation with elastic material
properties is performed.

FINITE ELEMENT ANALYSIS


Type of die, holder and punch are choosen as discrete rigid since defromations at at these parts will
be neglected. Type of blank is deformable.

Dkp-6112 is used as the blank material in the analysis. Mass density is 7.8E-09. Type of elastic
behavior is isotropic, Young’s modulus is 20000, poisson ratio is 0,32. For plastic behavior yield stress
and plastic strain values at below table used. These are true plastic strain vs. true stress values. These
values are obtained by subtracting elastic strains from total strain.

Yield Stress Plastic Strain


249.534 0.000
250.347 0.149
251.018 0.216
252.006 0.288
253.099 0.353
254.177 0.411
256.256 0.506
257.872 0.576
260.077 0.674
263.997 0.844
268.473 1.036
271.200 1.158
282.525 1.663
291.634 2.116
300.373 2.620
310.103 3.291
320.049 4.156
330.907 5.456
340.643 7.119
350.058 9.854
351.063 10.325
352.899 11.358
353.306 11.672
355.759 15.978
Assembly can be seen below.

A dynamic, explicit step is created with 0,1 seconds time.

Three interactions are defined. They are blank-die, blank-holder and blank-punch. Under tangential
behavior penalty friction formulation is used and as friction coefficient 0,1 is chosen. At all of the
interactions penalty contact method is used.

50000 N force is applied to holder is –z direction. Concentrated load is chosen since holder is a rigid
part.

There are four boundary conditions. Die is fixed, displacement of holder and punch is free at z
direction and velocity of punch is 20 in –z direction.

At Mesh part approximate global size for blank is chosen 10 and for other parts 12. For blank element
shape is quad-dominated and technique is sweep since this meshing shape is more suitable for this
deep drawing operation.
For blank total element number is 336, total node number is 337.

For die total element number is 222, total node number is 256.

For holder total element number is 234, total node number is 234.

For punch total element number is 123, total node number is 134.

For assembly total element number is 915, total node number is 961 which is very close to limit of
student edition ABAQUS.

RESULTS

As it can be seen from the above figure (S, Mises) max stress is 98,4 MPa which is smaller than yield
strength of the material so process is elastic. Maximum stress occurs at region where punch touches
to the blank.

All of the process is elastic and it can also be seen from the below figure (PE, Max). There is no plastic
strain.

Maximum displacement of the blank is 0,3 mm which can be seen from figure (U, U3).
CONCLUSION
Deep drawing process is modeled but only elastic deformation is examined. The punch pushes the
blank only 0,3 mm and after this point plastic deformation starts and will be examined detailed at
other reports.

While preparing this report using ABAQUS is learned and a simple finite element analysis is done.

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