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Learning Experience in Designing a Dome Test Setup for Sheet Metal Formability Characterization

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Conference

2017 ASEE Annual Conference & Exposition

Location

Columbus, Ohio

Publication Date

June 24, 2017

Start Date

June 24, 2017

End Date

June 28, 2017

Conference Session

Materials, Manufacturing, and Machine Component Design

Tagged Division

Mechanical Engineering

Page Count

29

Permanent URL

https://peer.asee.org/28611

Download Count

473

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Paper Authors

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Monica Dore

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Monica Doré currently holds an engineering position at the National Aeronautics and Space Administration (NASA) at Wallops Flight Facility as an Aerospace engineer. Ms. Dore has received an Undergraduate Degree with Honors in Engineering with a Mechanical Specialization from the University of Maryland Eastern Shore (UMES) in December 2014. Prior to receiving her undergraduate degree she worked as an intern with NASA from 2012-2014. She works supporting Airborne Science missions aboard flight platforms such as the P-3 and C-130. She develops mechanical structures for integrating Earth science instruments into NASA aircrafts. The work involves developing, fabricating, and testing flight vehicle structures or their components and recommending optimum configurations, structural design, materials, and techniques. Her work is multi-faceted as she is responsible for completing a design from the concept stages and gathering requirements, to fabrication and assembly. This often entails being the design engineer, the structural analyst, and the fabrication drafter.

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Rodrigo Arturo Ramos University of Maryland, Eastern Shore

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Rodrigo Ramos’ Biography for 2017 ASEE Conference

Rodrigo Ramos, born in Santiago, Chile, is currently the Quality Control Manager at Sonic Tools LP, a business developing and supplying high quality, specialty tooling across a variety of manufacturing industries. He is also in a work committee dedicated to studying the ERP system in place, and correcting processes when necessary. Rodrigo received his Undergraduate Degree in Engineering with a specialization in Mechanical Engineering from the University of Maryland Eastern Shore. Prior to receiving his Undergraduate Degree, Rodrigo programmed and designed the Quality Control database during an internship at Sonic Tools LP. As an intern with MaTech Solutions, Rodrigo built 3D models of shop machines to be used for simulating programs and preventing machine crashes.

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Payam Matin University of Maryland, Eastern Shore

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Dr. Payam Matin is currently an Associate Professor in the Department of Engineering and Aviation Sciences at the University of Maryland Eastern Shore (UMES), Princess Anne, Maryland. Dr. Matin has received his Ph.D. in Mechanical Engineering from Oakland University, Rochester, Michigan in May 2005. He has taught a number of courses in the areas of mechanical engineering and aerospace at UMES. He has served as departmental ABET committee chair through a successful accreditation visit in Fall 2012. Dr. Matin’s research has been mostly in the areas of Computational Mechanics and Experimental Mechanics with applications in Solid Mechanics, Plasticity and Sheet Metal Forming. Dr. Matin has published more than 25 peer-reviewed journal and conference papers. Dr. Matin is the recipient of NSF MRI award as a Co-PI. Dr. Matin worked in Automotive industry for Chrysler Corporation from 2005 to 2007. He Joined UMES in August 2007. He is affiliated with ASME and ASEE professional societies

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Monai Stinnett University of Maryland Eastern Shore

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Monai Stinnett graduated in December 2014 with a Bachelor of Science Degree in General Engineering Specializing in Mechanical Engineering from University of Maryland Eastern Shore. Monai is currently enrolled at University of Maryland College Park Master Program pursuing in Mechanical Engineering, Energy and Environment. She wants to further her knowledge in Energy Engineering to focus on methods to effectively increase efficiency and to use energy in cleaner ways. For her Senior Design Project, Ms. Stinnett Designed a Dome Test Setup for Sheet Metal Formability Characterization. During the summer of 2014, Ms. Stinnett had a Maryland Space Grant Consortium Summer Exchange Student Internship. She developed lab experiments that aid the learning of multiple manufacturing concepts through hands-on completion of the lab exercise. Integrating learning-based assessment tools into the designs of the experiments.

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Abstract

Dome test is one of the methods that is used in industry for characterization of sheet metal formability. Designing a dome test set up can provide undergraduate students with significant learning experience. The objective of this paper is to discuss the learning experience that has been gained by a team of undergraduate students in designing a dome test setup in a form of a senior design project. A dome test set up is consisted of a punch, die, and blank holder along with instrumentation. Through a contact, the punch forms a flat sheet metal specimen, which is held on its edge by the blank holder, into the cylindrical die cavity in a shape of a dome. The height of the dome is considered as a measure of formability. To achieve a set of pre-defined educational objectives, the design project is defined with specific design requirements and design constraints. Students have worked in a team framework to develop their detailed design approach under supervision of faculty. Students have learned to utilize commercial software ABAQUS for FEM forming simulation of dome test to estimate the maximum punch force needed for successful testing. Students have improved their Computer Aided Design skills in designing the punch, die, and blank holder including the draw beads that can stand the required force estimated by FEM. A force and position sensors are integrated in the design as instrumentation to measure the force and dome height at different stages of deformation. Students have collaborated to build the solid model of the system in SolidWorks. The proper design documentations have been prepared. The learning outcomes and educational benefits of the projects that have been gained throughout the course of two semesters are discussed.

Dore, M., & Ramos, R. A., & Matin, P., & Stinnett, M. (2017, June), Learning Experience in Designing a Dome Test Setup for Sheet Metal Formability Characterization Paper presented at 2017 ASEE Annual Conference & Exposition, Columbus, Ohio. https://peer.asee.org/28611

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