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Session number 2793

EXPERIMENTAL DESIGN STUDY OF METAL FORMING

Raghu Echempati and V.M.S. Sathya Dev

Mechanical Engineering Department Kettering University, Flint, MI - 48504

Abstract

In this paper, a statistical method of analysis based on design of experiments (DOE) and response surface has been used to study the optimum conditions of formability of aluminum sheet metal. Sheet metal forming deals with deforming thin sheets in to useful parts by stamping process. Usually the stamped parts undergo a combination of bending, drawing and/or stretching operations during a forming operation. A stamped part thus experiences three-dimensional strain, known as major strain, minor strain and thickness strain. Prior work done by many researchers and industrial establishments reveal that optimum set of stamping process parameters exists for parts made of steel. The goal of this research is to determine the optimum stamping conditions for a simple part made of aluminum material using the DOE. Future research aims at extending this single DOE to a series of experiments using the response surface methodology (RSM).

Introduction

Formability study on aluminum is gaining more and more importance in the last decade as aluminum stampings are extensively used in automobiles in order to gain in both cost and weight reduction of the vehicle. In metal forming processes, a lot of control parameters are to be taken care of to obtain successful stampings. This requires a complete knowledge and understanding of the process and the tooling parameters involved. One way of achieving this is to carry out a detailed process study by varying t he parameters across different levels. By this, a clear picture of the influence of each parameter on the process can be obtained. However, extensive number of tryouts are time consuming and very expensive. There are two ways of augmenting this. One is to adapt a statistical approach, to understand the influence and to optimize the parameters on the process, with minimum tryouts. A second way is to rely on computer simulation of forming processes or virtual forming during the early stages of part design. In this paper the statistical approach of aluminum formability study is dealt with.

Proceedings of the 2002 American Society for Engineering Education Annual Conference & Exposition Copyright Ó 2002, American Society for Engineering Education

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Sathya Dev, V., & Echempati, R. (2002, June), Experimental Design Study Of Metal Forming Paper presented at 2002 Annual Conference, Montreal, Canada. 10.18260/1-2--11137