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Analysis of sheet metal extrusion process using finite element method

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Abstract

Sheet bulk metal forming processes have been widely developed to the facilitate manufacture of complicated 3D parts. However, there is still not enough know-how available. In this paper, as one of the typical sheet bulk metal forming processes, the sheet metal extrusion process was studied. A reasonable finite element method (FEM) model of sheet metal extrusion process taking the influence of flow-stress curve with wide range of plastic strain and ductile damage into consideration was established and simulated by an arbitrary Lagrangian-Eulerian (ALE) FEM implemented in MSC. Marc. Validated by comparing the results with experiment, some phenomenological characteristics, such as metal flow behavior, shrinkage cavity, and the influence of different combinations of diameter of punch, diameter of extrusion outlet, and diameter of pre-punched hole were analyzed and concluded, which can be used as theoretical fundamental for the design of the sheet metal extrusion process.

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Authors and Affiliations

  1. Department of Plasticity Technology, Shanghai Jiao Tong University, Shanghai, 200030, PRC

    Xin-Cun Zhuang, Hua Xiang & Zhen Zhao

Authors
  1. Xin-Cun Zhuang
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  2. Hua Xiang
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  3. Zhen Zhao
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Corresponding author

Correspondence to Zhen Zhao.

Additional information

This work was supported by National Science & Technology Major Project of China (No. 2009ZX04014-073) and National Natural Science Foundation of China (No. 50975175).

Xin-Cun Zhuang received the B. Sc. and Ph.D. degrees in materials processing engineering from Shanghai Jiao Tong University, PRC in 2002 and 2008, respectively. Currently, he is a lecturer in the Department of Plasticity Technology at Shanghai Jiao Tong University.

His research interests include sheet bulk metal forming, numerical simulation method, and process optimization.

Hua Xiang received the B. Sc. and M. Sc. degrees in materials science and engineering from Central South Universality, PRC in 2000 and 2003, respectively. Currently, he is an engineer in the Department of Plasticity Technology at Shanghai Jiao Tong University, PRC, and continues to study for Ph. D. degree in material processing engineering.

His research interests include knowledgebased engineering, fineblanking, and sheet bulk metal forming.

Zhen Zhao received the B. Sc., M. Sc., and Ph.D. degrees in materials processing engineering from Shanghai Jiao Tong University, PRC in 1994, 1999, and 2002, respectively. Currently, he is a professor in the Department of Plasticity Technology at Shanghai Jiao Tong University.

His research interests include precision metal forming technology and intelligent design technology.

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Zhuang, XC., Xiang, H. & Zhao, Z. Analysis of sheet metal extrusion process using finite element method. Int. J. Autom. Comput. 7, 295–302 (2010). https://doi.org/10.1007/s11633-010-0506-8

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  • DOI: https://doi.org/10.1007/s11633-010-0506-8

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