effect of blank holder force and punch number on the forming...
TRANSCRIPT
![Page 1: Effect of Blank Holder Force and Punch Number on the Forming …ijens.org/Vol_18_I_04/180304-6969-IJMME-IJENS.pdf · 2018. 8. 20. · presented by using Matlab program as shown in](https://reader036.vdocument.in/reader036/viewer/2022081411/60a6fcc44cccbf2f68274922/html5/thumbnails/1.jpg)
International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:18 No:04 56
I J E N S August 2018 IJENS IJENS © -IJMME-6969-401803
Effect of Blank Holder Force and Punch Number on
the Forming Behavior of Conventional Dies Ragad Aziz Neama1, Maher A.R. Sadiq Al-Baghdadi2, Muhannad Al-Waily3
1University of Kufa, Faculty of Engineering, Mechanical Engineering Department, Iraq, [email protected] 2University of Kufa, Faculty of Engineering, Mechanical Engineering Department, Iraq, [email protected]
3University of Kufa, Faculty of Engineering, Mechanical Engineering Department, Iraq, [email protected]
Abstract— The circular multi-point forming (CMPF) is a
flexible technique in which the fixed shape of conventional dies is
replaced by two matrices of moveable punch elements called
upper and lower punch grope. This paper focuses on design,
simulation and manufacture of circular multi point die to
produce several forms of product by using one die. This die
designed by Auto cad program, and third degree with four
control point points open uniform B-spline approximation
technique was adopted to represent the bending surface by using
MATLAB software program. The coordinate of each point of
surface taken from this program to create the by adjusting the
height of each punch manually. Finite element method software
(ANSYS 15) was used to simulate the circular forming process
numerically and due to symmetry of product only one quarter
surface of circular MPD was simulated. Aluminum 1070 plate
with 1mm thickness has been chosen. The effect of (1,3,5 kN)
blank holder force and (17*17, 25*25) number of pins has been
studied numerically in term of stress and strain distribution and
thickness variation. The experimental work involved
manufacturing circular MPD and forming required product by
insertion and absence of (2 mm) rubber to show the effect of
interpolator on dimpling and thickness variation along the sheet
metal. The results showed that the insertion of (2 mm) rubber
interpolator and (3 kN) blank holder force is the best to avoid the
dimpling, wrinkling defect and give good stress, strain
distribution and thickness variation.
Index Term— Multi Point Forming, Interpolator, Blank Holder
Force, Punch Effect, Forming Several Parts.
I. INTRODUCTION
Sheet metal forming is one of best commonly used techniques
to form the part shape. In conventional forming the die is
designed to manufacture on shape product only and different
part form required dissimilar dies, but the dies are expensive
and require long time to complete the industrial ,the use of this
technique is inefficient where produce single product. For this
reason, the move able discrete die has been advanced , which
can be used to produce a number of products with different
shapes by small cost, [1]. Shaohui et. al, [2], introduced the
numerical simulation of multi point stretch forming process
for spherical, saddle ,and cylindrical shape part. The local
stress and local strain in thickness variation distribution of
MPSF were analyzed by dispersed the blank in to solid
element and also study the effect of punch size on stress
concentration. The results presented that the local stress ,local
strain and punch with small size can decrease the stress
distribution. M-Z Li et. al, [3], described the principle of
multi-point matched die forming (MPMDF) and introduced
the equipment of its die. Seong et. al, [4], constructed the
numerical simulation model for saddle typed thick plate
forming process including the spring back analysis to predict
the forming performance. Abdulkareem et. al, [5], achieved
the numerical simulation for sheet metal to study the effect of
number and head shape of pins in term of stress distribution
and shape accuracy. Hani et. al, [6], studied the effect of
elastic cushion thickness and radii of punch group on dimpling
defect. Therefore, the presented paper did not investigation die
with circular shapes, in addition to, it’s did not studied the
problem numerically by Ansys program, finite element
techniques. Then, this paper differ from the others researchers
by the different important points, first, this die designed by
Auto cad program, second, third degree open uniform B-spline
surface was derivative to represent the bending surface by
using Matlab program, third, 3-D finite element method Ansys
15 was used to simulate the circular forming process
numerically to study the effect of BHF and rubber interpolator
along the axial and circumference path and then get the best
design to avoid the dimpling, wrinkling defect and give good
stress, strain distribution and thickness variation, and finally,
due to ability of forming different shape with single die, this
die has been manufactured.
II. MATHEMATICAL MODEL
This curve is estimate curve which consist of more segment
each one effected and defined by control points by using
special set of basis function. The mathematical definition of
this curve is,
p(t) = ∑ Pi Ni,kni=0 (t) (1)
Wherever Pi, 𝑘 represent the control point and the number of
its respectively. Ni,k is the B-spline basis function which have
two mathematical definitions,
1. When 𝑘 = 1, 𝑁𝑖,1(𝑡) = {1 𝑖𝑓 𝑡𝑖 ≤ 𝑡 < 𝑡𝑖+1
0 𝑜𝑡ℎ𝑒𝑟𝑤𝑖𝑠𝑒 (2)
2. When 𝑘 > 1, 𝑁𝑖,𝑘(𝑡) = ((
𝑡−𝑡𝑖
𝑡𝑖+𝑘−1−𝑡𝑖) 𝑁𝑖,𝑘−1(𝑡) +
(𝑡𝑖+𝑘−𝑡
𝑡𝑖+𝑘−𝑡𝑖+1) 𝑁𝑖+1,𝑘−1(𝑡)
) (3)
The knot in open uniform B-spline curve requires three
condition, [7],
𝑡𝑖 = 0 𝑖𝑓 𝑖 < 𝑘 𝑡𝑖 = 𝑖 − 𝑘 + 1 𝑖𝑓 𝑘 ≤ 𝑖 ≤ 𝑛
𝑡𝑖 = 𝑛 − 𝑘 + 2 𝑖𝑓 𝑖 > 𝑛 } 0 ≤ 𝑖 ≤ 𝑛 + k (4)
The basis function with 𝑘 = 𝑛 = 3 of open uniform B-spline
curve was derived and the number of control points, segment
and knots in knot vector are four, two, and seven respectively.
![Page 2: Effect of Blank Holder Force and Punch Number on the Forming …ijens.org/Vol_18_I_04/180304-6969-IJMME-IJENS.pdf · 2018. 8. 20. · presented by using Matlab program as shown in](https://reader036.vdocument.in/reader036/viewer/2022081411/60a6fcc44cccbf2f68274922/html5/thumbnails/2.jpg)
International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:18 No:04 57
I J E N S August 2018 IJENS IJENS © -IJMME-6969-401803
The knot vector is, [0 0 0 1 2 2 2], and the basic
functions at 𝑘 = 1 and from Eq. 2. are, 𝑁0,1 = 𝑁1,1 = 0
because 0 ≤ 𝑡 < 0, 𝑁2,1 = 1 because 0 ≤ 𝑡 < 1, and 𝑁3,1 = 1
for 1 ≤ t < 2, N4,1 = N5,1 = 0 because 2 ≤ t < 2.
The basic functions at 𝑘 = 2 and from equation 3 are,
𝑁0,2(𝑡) =(𝑡−0)
(0−0)𝑁0,1(𝑡) +
(0−𝑡)
(0−0)𝑁1,1(𝑡) = 0
𝑁1,2(𝑡) =(𝑡−0)
(0−0)𝑁1,1(𝑡) +
(1−𝑡)
(1−0)𝑁2,1(𝑡) = (1 − 𝑡) 0 ≤ 𝑡 < 1
𝑁2,2(𝑡) =(𝑡−0)
(1−0)𝑁2,1(𝑡) +
(2−𝑡)
(2−1)𝑁3,1(𝑡) = {
𝑡 0 ≤ 𝑡 < 1(2 − 𝑡) 1 ≤ 𝑡 < 2
𝑁3,2(𝑡) =(𝑡−1)
(2−1)𝑁3,1(𝑡) +
(2−𝑡)
(2−2)𝑁4,1(𝑡) = (𝑡 − 1) 1 ≤ 𝑡 < 2
(5)
And 𝑁4,2(𝑡) = 0. During the calculation of B-spline surface
any value divided by zero is equal to zero, [7].
The basic functions at k = 3 and also from Eq. 3. are,
𝑁0,3(𝑡) =(𝑡−0)
(0−0)𝑁0,2(𝑡) +
(1−𝑡)
(1−0)𝑁1,2(𝑡) = (1 − 𝑡)2 0 ≤ 𝑡 < 1
𝑁1,3(𝑡) =(𝑡−0)
(1−0)𝑁1,2(𝑡) +
(2−𝑡)
(2−0)𝑁2,2(𝑡)
= {(𝑡(1 − 𝑡) +
1
2𝑡(2 − 𝑡)) 0 ≤ 𝑡 < 1
1
2(2 − 𝑡)2 1 ≤ 𝑡 < 2
𝑁2,3(𝑡) =(𝑡−0)
(2−0)𝑁2,2(𝑡) +
(2−𝑡)
(2−1)𝑁3,2(𝑡)
= {
1
2𝑡2 0 ≤ 𝑡 < 1
1
2(2 − 𝑡)𝑡 + (2 − 𝑡)(𝑡 − 1) 1 ≤ 𝑡 < 2
𝑁3,3(𝑡) =(𝑡−1)
(2−1)𝑁3,2(𝑡) +
(2−𝑡)
(2−2)𝑁4,2(𝑡) = (𝑡 − 1)2 1 ≤ 𝑡 < 2
(6)
Two different basis function will be produced after
compensate these equations. The matrix form of this basis
functions are,
𝑀𝑏1 =1
2[
2 −3 1−4 4 02 0 0
] , 𝑀𝑏2 =1
2[
1 −3 2−4 8 −44 −4 2
]
𝑃1(𝑡) =1
2[𝑡2 𝑡 1] [
2 −3 1−4 4 02 0 0
] [
𝑝0
𝑝1
𝑝2
]
𝑃2(𝑡) =1
2[𝑡2 𝑡 1] [
1 −3 2−4 8 −44 −4 2
] [
𝑝1
𝑝2
𝑝3
] (7)
The curve of open uniform B-spline with (𝑛 = 𝑘 = 3) is
consists of two segments and the surface of its consist of four
segment and due to symmetry only one quarter part of surface
presented by using Matlab program as shown in Fig. 1.
Fig. 1. One Quarter of B-Spline Surface by Matlab Program.
III. FINITE ELEMENT TECHNIQUE
The numerical technique include analysis the problem by
using Ansys program, ver. 15. This program is capable to
solve a wide range of problems, [8-18]. Thus, the results for
numerical techniques are given accepted approximant solution
for problem with agreement error comparison with other
techniques were used, [19-29]. Then, the modeling for any
problem by Ansys program required at first selected the
element types required for application, [30-34], and then
modeling the case by different procedure. The preprocessor
icon is used to choose the element type, define material
properties, and create the model geometry. In current study the
important stage to develop the FE model are,
a. Define the element type, in current study the elements used
to simulate the blank is solid 185, as shown in Fig. 2, the
contact and target elements are CONTA 174 and TARGE
170, as shown in Fig. 3 and Fig. 4, respectively.
Therefore, the element type solid 185 is use to 3-D structure
and also using for different application as,
i. Large deflection and strain
ii. Plasticity
iii. Stiffening stress
Where, the degree of freedom for element solid 185 are three
degree of freedom as displacement in x, y, and z-direction, 𝑈𝑥,
𝑈𝑦, and 𝑈𝑧. Also, it’s element use the techniques for solution
for �̅� method at Gauss integration point. Thus, the input data
required for element are the mechanical properties for the
structure, and, the output data for it element are included the
stress and strain solution for structure.
Then, using element conta-174 to contact and sliding between
a deformable surface and surface for 3-D target, as shown in
Fig. 3. Where, it element also used to 3-D structure
application. In addition, using targe-170 element to contact the
conta-174 element with the 3-D surface for target, as in Fig. 4.
b. Create the model geometry, the height of each pin taking
from Matlab program and then entered to Ansys program
to generate the same surface profile. Due to symmetry in
geometry, boundary condition and the loading one quarter
part of the 3D model needed are created and analyzed as
shown in Fig. 5.
c. Define the material properties, The material properties of
AL 1070 is defined by modulus of elasticity and yield
stress σy taken from experimental part.
d. Generation the mesh, the meshing stage is important step
that used to convert the geometrical model to finite
element model.
e. Generation the contact, this stage constitute of four contact
pairs : between the holder and work piece, upper punches
and work piece, lower punches and work piece, and finally
between the die and holder.
f. Applying load and solution, the load is applied by five
steps .The first step is defined by applying of the holder
force and the other steps defined by applying the
movement on the upper punches to travel in opposite Y-
axis as displacement that is equal to the height of product,
then solve from load step file.
![Page 3: Effect of Blank Holder Force and Punch Number on the Forming …ijens.org/Vol_18_I_04/180304-6969-IJMME-IJENS.pdf · 2018. 8. 20. · presented by using Matlab program as shown in](https://reader036.vdocument.in/reader036/viewer/2022081411/60a6fcc44cccbf2f68274922/html5/thumbnails/3.jpg)
International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:18 No:04 58
I J E N S August 2018 IJENS IJENS © -IJMME-6969-401803
Fig. 2. Geometry of Element Type Solid 185.
Fig. 3. Geometry of Element Type Conta-174.
Fig. 4. Geometry of Element Type Targe-170.
Fig. 5. The FEM of Circular MPD.
IV. EXPERIMENTAL WORK
The aim of this part are testing , manufacturing and forming
the work piece. The 1mm Aluminum alloy (1070) sheet which
is used as a work piece. IV.1. Testing process
In which the metal is tested by using WDW model (100D3)
with 100 kN load capacity shown in Fig. 6. to determine its
mechanical properties, [35-42]. The specimens were loaded
till fracture occurs, with 2mm/min across head speed the
tensile test was done Fig. 7. shows the engineering stress
strain curve. The mechanical properties such as yield stress
and young's modulus are calculated from the tensile test and
equal to (70.5 Mpa and 70 Gpa, respectively).
Fig. 6. Universal Tensile Test Machine
Fig. 7. Stress-Strain Relation
IV.2. Designing and Manufacturing The CMPD
The CMPD is consist of upper and lower multi-point die
(UMPD and LMPD), each one consist of (25 pin). The
LCMPD is consist of (the base, the plate contains 25 holes,
and the die structure) are connected together. The UCMPD
consist of (the blank holder ,base , and the plate with 25
holes). The blank holder consist of four parts (circular thick
plate with (50 and 75 mm) inner and outer radius, three shafts
,three bolt, and three springs). The upper plate contains the
working array and three holes to insert the BH shaft through it,
this plate welded with the upper base and then the results parts
connected with the blank holder.
The die structure diameter and thickness are (150 mm and 10
mm) respectively, and the fillet radius is (3 mm) to certify
Upper
Supported
Lower
Supported
Tensile
Sample
Control
Guide
![Page 4: Effect of Blank Holder Force and Punch Number on the Forming …ijens.org/Vol_18_I_04/180304-6969-IJMME-IJENS.pdf · 2018. 8. 20. · presented by using Matlab program as shown in](https://reader036.vdocument.in/reader036/viewer/2022081411/60a6fcc44cccbf2f68274922/html5/thumbnails/4.jpg)
International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:18 No:04 59
I J E N S August 2018 IJENS IJENS © -IJMME-6969-401803
easy flow of work piece material into the die cavity, the length
of horizontal and vertical edge are (25 mm and 80 mm)
respectively as shown in Fig. 8.a. The outer, inner diameter
and thickness of upper and lower base are (150, 100 and 10
mm) respectively, the height of the lower and upper base are
(90 mm and 80 mm) as shown in Fig. 8.b. The lower and
upper plates diameter and thickness are (150 and 10 mm),
respectively, which consist of 25 hole ,each hole has (8 mm)
diameter and the distance between them is (12 mm) as shown
in Fig. 8.a. and in Fig. 8.c. Fig. 8.d. shows the blank holder
parts, the dimensions of blank holder plate are the same of
upper and lower base. This plate contains three shafts with
(125 mm) length and (10 mm) diameter and each shaft contain
spring with (110 mm length and 18 mm diameter) and the
effective stiffness of each spring (𝐾𝑒 = 75 𝑁/𝑚𝑚). Spherical
pin with 6.5 mm radius is used in this work. The diameter and
length of pin body is 8mm and 130 mm respectively. Fig. 9.
a. shows the upper and lower punch matrix. Fig. 9. b. shows
the CMPD with and without punch matrix.
Auto Cad Experimentally
a. Die frame and lower plate
b. Lower and Upper Base c. Upper Plate
Auto Cad Experimentally
d. Blank Holder Parts Fig. 8. The MPD Parts.
a. The Upper and Lower Punch Matrix
b. The CMPD with Punch Matrix.
Fig. 9. CMPD Combined.
IV.3. The Forming Process
In this stage the UMPD moved with (20 mm) in Y-axis to
produce the required height of the product after applying the
BHF. CMPD was pressed by using WDW model (100D3)
during the forming stage. In the first stage of forming the force
is small because a few punches are in contact with work piece,
and its force increase slowly by increasing the contact area.
The forming force reach to the maximum value when all
punches contact with work piece and the forming process was
completed.
V. RESULTS AND DISCUSSION
V.1. Study the Effect of BHF and Punch Number
The characteristics of a product are analyzed using FEM and
to simulate the forming process, the ANSYS ver. 15 has been
used. In the simulation the effect of punches number with
(1,3,5 kN) BHF has been studied. During the forming process
the wrinkling defect its appear, this defect can be avoided by
using the BHF, which holds the work piece at the edge and
prevent this failure. Two grope of punch elements with (6.5
mm) radius has been studied the first one is (17*17) and the
other is (25*25) punches number. The simulation is applied on
(1 mm) Al plate thickness. Fig. 10. to Fig. 15. show the Von-
Mises stress distributed along the circumference and below the
final pin row with (1, 3, 5 kN) BHF. From these results, it can
be showed that the plastic deformation occur and maximum
values of stress with (25 pin) in each upper and lower circular
MPD and (17 pin) in each upper and lower circular MPD are
![Page 5: Effect of Blank Holder Force and Punch Number on the Forming …ijens.org/Vol_18_I_04/180304-6969-IJMME-IJENS.pdf · 2018. 8. 20. · presented by using Matlab program as shown in](https://reader036.vdocument.in/reader036/viewer/2022081411/60a6fcc44cccbf2f68274922/html5/thumbnails/5.jpg)
International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:18 No:04 60
I J E N S August 2018 IJENS IJENS © -IJMME-6969-401803
(128 and 126 Mpa) respectively, as shown in Fig. 16, these
value exceed the yield stress. The wrinkling defect can be
removed by increasing the holder force. Fig. 17 to 22
represent the von Mises stress, strain distribution and depth of
deformation in Y-axis on one quarter of product with (1,3,5
kN) BHF and (25,17) punch.
The results shows that (1 kN) isn’t enough to hold the plate
and with increasing of holder force to (5 kN) the von misses
stress and strain distribution increase, so the work piece can be
deformed with (3 kN) BHF, and from the depth of
deformation its can be concluded that the wrinkling defect can
be avoided with 25 punch element and 3 kN BHF as shown in
Fig. 23. The dimples appear at the point where the punch in
contact with plate and change the thickness of the product it
can be seen clearly from thickness variation as shown in Fig.
24 to 26. The results show that with (17) punch number the
curve fluctuated extensively and the stress doesn't distributed
uniformly this indicated that the dimple defect on product
appear. when the number of punch is (25) the dimple get
minor and stress distributed uniformly on the final product and
the fluctuation of curve is small but also effect on the product
quality, so (2 mm) elastic cushion is used during the forming
experimentally to enhance the final product. Fig. 27. represent
the whole final product numerically.
Fig. 10. The Von-Mises Stress with 25 Pin and1 kN BHF.
Fig. 11. The Von-Mises Stress with 25 Pin and 3 kN BHF.
Fig. 12. The Von-Mises Stress with 25 pin and 5 kN BHF.
Fig. 13. The Von-Mises Stress with 17 Pin and 1 kN BHF.
Fig. 14. The Von-Mises Stress with 17 Pin and 3 kN BHF.
![Page 6: Effect of Blank Holder Force and Punch Number on the Forming …ijens.org/Vol_18_I_04/180304-6969-IJMME-IJENS.pdf · 2018. 8. 20. · presented by using Matlab program as shown in](https://reader036.vdocument.in/reader036/viewer/2022081411/60a6fcc44cccbf2f68274922/html5/thumbnails/6.jpg)
International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:18 No:04 61
I J E N S August 2018 IJENS IJENS © -IJMME-6969-401803
Fig. 15. The Von-Mises Stress with 17 Pin and 5 kN BHF.
Fig. 16. Von-Mises with Different Holder Force and Pin Number.
Fig. 17. Strain Distribution Along the x Axis with 17 Pin and (1,3,5 kN) BHF.
Fig. 18. Strain Distribution Along the x Axis with 25 Pin and (1,3,5 kN) BHF.
Fig. 19. Strain Distribution Along the x-Axis with (25,17) Punch, 3 kN BHF.
Fig. 20. Von Misses Stress Along the Circumference below Final Pin Row
with 25 Pin under (1,3,5 kN) BHF.
Fig. 21. Von Stress Along the Circumference Below Final Pin Row with 17
Pin under (1,3,5 kN) BHF.
Fig. 22. Von Stress Along the Circumference below Final Pin Row with
(17,25) Pin under 3 kN BHF.
![Page 7: Effect of Blank Holder Force and Punch Number on the Forming …ijens.org/Vol_18_I_04/180304-6969-IJMME-IJENS.pdf · 2018. 8. 20. · presented by using Matlab program as shown in](https://reader036.vdocument.in/reader036/viewer/2022081411/60a6fcc44cccbf2f68274922/html5/thumbnails/7.jpg)
International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:18 No:04 62
I J E N S August 2018 IJENS IJENS © -IJMME-6969-401803
Fig. 23. The Deformation in Y-Axis with 25 Pin under (1,3,5 kN) BHF.
Fig. 24. Thickness Variation Along Circumference below Final Pin Row with
25 Pin under (1,3,5 kN) BHF.
Fig. 25. Thickness Variation Along Circumference below Final Pin Row with
17 pin under (1,3,5 kN) BHF.
Fig. 26. Thickness Variation Along Circumference below Final Pin Row with
(25 and 17) Pin under 3 kN BHF.
Fig. 27. The Whole Final Product Numerically.
V.2. Study the Effect of Interpolator on Dimpling Defect
The surface of MPD is composed of discrete pins and the
pressure localized in some regions dependent on the pin
position ,so that the dimples can be formed in a product. There
are more dimples distributed on the product due to the position
of the punches in the upper and lower MPD as shown in Fig.
28.a. The best method to eliminate and remove this defect is to
insert the (2 mm) interpolator as shown in Fig. 28.b. The
thickness variation from the central distance along a long the
x-axis with and without (2 mm) rubber thicknesses
numerically and experimentally are shown in Fig. 29, from
figures it can be seen that to avoid the thickness variation, a (2
mm) rubber should be used.
a. Without Interpolator b. With 2 mm Rubber Interpolator
Fig. 28. Effect of Rubber Interpolator.
Fig. 29. Variation Thickness Along the X-Axis from the Center Distance with
and without (2 mm) Rubber Numerically and Experimentally.
No Dimpling Dimpling
![Page 8: Effect of Blank Holder Force and Punch Number on the Forming …ijens.org/Vol_18_I_04/180304-6969-IJMME-IJENS.pdf · 2018. 8. 20. · presented by using Matlab program as shown in](https://reader036.vdocument.in/reader036/viewer/2022081411/60a6fcc44cccbf2f68274922/html5/thumbnails/8.jpg)
International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:18 No:04 63
I J E N S August 2018 IJENS IJENS © -IJMME-6969-401803
VI. CONCLUSION
Extensive numerical simulation of CMPF process has been
carried out by finite element method using solid185 element.
The von-misses stress, strain, deformation, and thickness
variation was investigated in different directions. The effect of
BHF and punch number were analyzed. From the results, it
can be conclude that,
1. The numerical technique is a good tool can be used to
evaluating the Von-Mises stress and strain for product,
with comparison with experimental technique used.
2. 1 kN BHF isn’t enough to hold the plate and with
increasing force to 5 kN the von stress and strain
distribution increase, so the work piece can be deformed
with (3 kN) BHF.
3. From the depth of deformation its can be concluded that
the wrinkling defect can be avoided with 25 punch element
and 3 kN BHF.
4. The punch element exerted the concentrated load on work
piece and the product will be dimpled by the tip of punches
that appear at the point where the punch in contact with
plate and change the thickness of the product, so 2 mm
rubber interpolator necessary used to avoid this defect and
produce the product with good thickness variation.
REFERENCES [1] Z-Y Cai, S. H. Wang, M. Z. Li. ‘Numerical Investigation of Multi-Point
Forming Process for Sheet Metal: Wrinkling, Dimpling and Springback’ The International Journal of Advanced Manufacture Technology, Vol.
37, No. 9-10, pp. 927-936, 2008.
[2] S.Wang, Z.Cai, M. Li, Y. Lan ‘Numerical Simulation on the Local Stress and Local Deformation in Multi-Point Stretch Forming Process’
The International Journal of Advanced Manufacture Technology, Vol.
60, No. 9-12, pp. 901-911, 2012.
[3] M. Z. Li, Z. Y Cai, Z. Sui, X. J. Li ‘Principle and Applications of Multi-
Point Matched-Die Forming for Sheet Metal’ Proceedings of the
Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 222, No. 05, pp. 581-589, 2008.
[4] S. C. Heo, Y. H. Seo, T. W. Ku, B. S. Kang ‘A Study on Thick Plate
Forming using Flexible Forming Process and Its Application to a Simply Curved Plate’ The International Journal of Advanced Manufacture
Technology, Vol. 51, No. 1-4, pp. 103-115, 2010.
[5] A. J. Kadhim, M. I. Abbas ‘Influence of Die Elements Shapes on Process Parameters in Multi-Point Sheet Metal Forming Process’
Economics and Social Sciences, 2013.
[6] H. A. Ameen, H. A. Alsabti, Z. A. Radhi ‘Finite Element Analysis of the Dish Multi-Point Forming Process’ International Journal of Engineering
Research &Technology, Vol. 05, No. 07, 2016.
[7] R. A. Neama ‘Numerical and Experimental Investigation of Multi Point Die Forming’ M.Sc. Thesis, University of Babylon, Iraq, 2015.
[8] Muhsin J. Jweeg ‘Application of finite element analysis to rotating fan
impellers’ Doctoral Thesis, Aston University, 1983.
[9] Luay S. Al-Ansari, Muhannad Al-Waily, Ali M. H. Yusif ‘Vibration
Analysis of Hyper Composite Material Beam Utilizing Shear
Deformation and Rotary Inertia Effects’ International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS, Vol. 12, No.
04, 2012.
[10] Muhsin J. Jweeg, Ali S. Hammood, Muhannad Al-Waily ‘A Suggested Analytical Solution of Isotropic Composite Plate with Crack Effect’
International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS, Vol. 12, No. 05, 2012.
[11] Ayad M. Takhakh, Fahad M. Kadhim, Jumaa S. Chiad ‘Vibration
Analysis and Measurement in Knee Ankle Foot Orthosis for Both Metal and Plastic KAFO Type’ ASME 2013 International Mechanical
Engineering Congress and Exposition IMECE2013, November 15-21,
San Diego, California, USA, 2013.
[12] Muhannad Al-Waily, Zaman Abud Almalik Abud Ali ‘A Suggested
Analytical Solution of Powder Reinforcement Effect on Buckling Load
for Isotropic Mat and Short Hyper Composite Materials Plate’
International Journal of Mechanical & Mechatronics Engineering
IJMME-IJENS, Vol. 15, No. 04, 2015. [13] Muhannad Al-Waily, Alaa Abdulzahra Deli, Aziz Darweesh Al-
Mawash, Zaman Abud Almalik Abud Ali ‘Effect of Natural Sisal Fiber
Reinforcement on the Composite Plate Buckling Behavior’ International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS,
Vol. 17, No. 01, 2017.
[14] Muhsin J. Jweeg, A. A. Alhumandy, H. A. Hamzah ‘Material Characterization and Stress Analysis of Openings in Syme’s Prosthetics’
International Journal of Mechanical & Mechatronics Engineering
IJMME-IJENS, Vol. 17, No. 04, 2017. [15] Muhannad Al-Waily, Kadhim K. Resan, Ali Hammoudi Al-Wazir,
Zaman Abud Almalik Abud Ali ‘Influences of Glass and Carbon
Powder Reinforcement on the Vibration Response and Characterization of an Isotropic Hyper Composite Materials Plate Structure’ International
Journal of Mechanical & Mechatronics Engineering IJMME-IJENS,
Vol. 17, No. 06, 2017. [16] Rasha Hayder Al-Khayat, Maher A. R. Sadiq Al-Baghdadi, Ragad Aziz
Neama, Muhannad Al-Waily ‘Optimization CFD Study of Erosion in
3D Elbow During Transportation of Crude Oil Contaminated with Sand Particles’ International Journal of Engineering & Technology, Vol. 07,
No. 03, pp. 1420-1428, 2018.
[17] Ayad M. Takhakh ‘Manufacturing and Analysis of Partial Foot Prosthetic for The Pirogoff Amputation’ International Journal of
Mechanical & Mechatronics Engineering IJMME-IJENS, Vol. 18, No. 03, pp. 62-68, 2018.
[18] Saif M. Abbas, Ayad M. Takhakh, Mohsin Abdullah Al-Shammari,
Muhannad Al-Waily ‘Manufacturing And Analysis Of Ankle Disarticulation Prosthetic Socket (SYMES)’ International Journal of
Mechanical Engineering and Technology, Vol. 09, No. 07, 2018.
[19] Maher A.R. Sadiq Al-Baghdadi ‘A CFD Study of Hygro-Thermal Stresses Distribution in PEM Fuel Cell During Regular Cell Operation’
Renewable Energy Journal, Vol. 34, No. 03, pp.674-682, 2009.
[20] Maher A. R. Sadiq Al-Baghdadi ‘Prediction of Deformation and Hygro-Thermal Stresses Distribution in Ambient Air-Breathing PEM Fuel
Cells using Three-Dimensional CFD Model’ Recent Patents on
Mechanical Engineering, Vol. 02, No. 01, pp. 26-39, 2009. [21] Maher A. R. Sadiq Al-Baghdadi ‘A CFD Analysis of Transport
Phenomena and Electrochemical Reactions in a Tubular-Shaped
Ambient Air-Breathing PEM Micro Fuel Cell’ HKIE Transactions Hong Kong Institution of Engineers, Vol. 17, No. 02, 2010.
[22] Muhsin J. Jweeg, Sameer Hashim Ameen ‘Experimental and theoretical
investigations of dorsiflexion angle and life of an ankle-Foot-Orthosis made from (Perlon-carbon fibre-acrylic) and polypropylene materials’
10th IMEKO TC15 Youth Symposium on Experimental Solid
Mechanics, 2011. [23] Muhsin J. Jweeg, Kadhim K. Resan, Mustafa Tariq Ismail ‘Study of
Creep-Fatigue Interaction in a Prosthetic Socket Below Knee’ ASME
International Mechanical Engineering Congress and Exposition, 2012. [24] Mohsin Abdullah Al-Shammari, Muhannad Al-Waily ‘Theoretical and
Numerical Vibration Investigation Study of Orthotropic Hyper
Composite Plate Structure’ International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS, Vol. 14, No. 06, 2014.
[25] Muhsin J. Jweeg, Muhannad Al-Waily, Alaa Abdulzahra Deli
‘Theoretical and Numerical Investigation of Buckling of Orthotropic Hyper Composite Plates’ International Journal of Mechanical &
Mechatronics Engineering IJMME-IJENS, Vol. 15, No. 04, 2015.
[26] Muhannad Al-Waily, Maher A.R. Sadiq Al-Baghdadi, Rasha Hayder Al-Khayat ‘Flow Velocity and Crack Angle Effect on Vibration and
Flow Characterization for Pipe Induce Vibration’ International Journal
of Mechanical and Mechatronics Engineering IJMME-IJENS, Vol. 17, No. 05, pp.19-27, 2017.
[27] Muhsin J. Jweeg, E. Q. Hussein, K. I. Mohammed ‘Effects of Cracks on
the Frequency Response of a Simply Supported Pipe Conveying Fluid’ International Journal of Mechanical & Mechatronics Engineering
IJMME-IJENS, Vol. 17, 05, 2017.
[28] Mahmud Rasheed Ismail, Muhannad Al-Waily, Ameer A. Kadhim ‘Biomechanical Analysis and Gait Assessment for Normal and Braced
![Page 9: Effect of Blank Holder Force and Punch Number on the Forming …ijens.org/Vol_18_I_04/180304-6969-IJMME-IJENS.pdf · 2018. 8. 20. · presented by using Matlab program as shown in](https://reader036.vdocument.in/reader036/viewer/2022081411/60a6fcc44cccbf2f68274922/html5/thumbnails/9.jpg)
International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:18 No:04 64
I J E N S August 2018 IJENS IJENS © -IJMME-6969-401803
Legs’ International Journal of Mechanical & Mechatronics Engineering
IJMME-IJENS, Vol. 18, No. 03, 2018.
[29] Mohsin Abdullah Al-Shammari, Lutfi Y. Zedan, Akram M. Al-
Shammari ‘FE simulation of multi-stage cold forging process for metal
shell of spark plug manufacturing’ 1st International Scientific Conference of Engineering Sciences-3rd Scientific Conference of
Engineering Science, ISCES 2018–Proceedings, 2018.
[30] Abdulkareem Abdulrazzaq Alhumdany, Muhannad Al-Waily, Mohammed Hussein Kadhim Al-Jabery ‘Theoretical and Experimental
Investigation of Using Date Palm Nuts Powder into Mechanical
Properties and Fundamental Natural Frequencies of Hyper Composite Plate’ International Journal of Mechanical & Mechatronics Engineering
IJMME-IJENS, Vol. 16, No. 01, 2016.
[31] Muhsin J. Jweeg ‘A Suggested Analytical Solution for Vibration of Honeycombs Sandwich Combined Plate Structure’ International Journal
of Mechanical & Mechatronics Engineering IJMME-IJENS, Vol. 16,
No. 02, 2016. [32] Ahmed M. Hashim, E. K. Tanner, Jawad K. Oleiwi ‘Biomechanics of
Natural Fiber Green Composites as Internal Bone Plate Rafted’ MATEC
Web of Conferences, 2016. [33] Ameer A. Kadhim, Muhannad Al-Waily, Zaman Abud Almalik Abud
Ali, Muhsin J. Jweeg, Kadhim K. Resan ‘Improvement Fatigue Life and
Strength of Isotropic Hyper Composite Materials by Reinforcement with Different Powder Materials, International Journal of Mechanical &
Mechatronics Engineering IJMME-IJENS, Vol. 18, No. 02, 2018.
[34] Jawad K. Oleiwi, Ahmed Namah Hadi ‘Experimental and numerical investigation of lower limb prosthetic foot made from composite
polymer blends’ International Journal of Mechanical and Production Engineering Research and Development, Vol. 08, No. 02, pp. 1319-
1330, 2018.
[35] Ghaith G. Hameed, Muhsin J. Jweeg, Ali Hussein ‘Springback and side wall curl of metal sheet in plain strain deep drawing’ Research Journal
of Applied Sciences, Vol. 04, No. 05, pp. 192-201, 2009.
[36] Muhsin J. Jweeg, Ali S. Hammood, Muhannad Al-Waily ‘Experimental and Theoretical Studies of Mechanical Properties for Reinforcement
Fiber Types of Composite Materials’ International Journal of
Mechanical & Mechatronics Engineering IJMME-IJENS, Vol. 12, No. 04, 2012.
[37] Adnan S. Jabur, Jalal M. Jalil, Ayad M. Takhakh ‘Experimental
Investigation and Simulation of Al-Si Casting Microstructure Formation’ Arabian Journal for Science and Engineering, Vol. 37, No.
03, pp. 777-792, 2012.
[38] Ayad M. Takhakh, Raied Z. Alfay, Abdul Rahim K. Abid Ali ‘Effect of Ta addition on hardness and wear resist of Cu-Al-Ni shape memory
alloy fabricated by powder metallurgy’ BEIAC 2013-2013 IEEE
Business Engineering and Industrial Applications Colloquium, 2013. [39] Mohsin Abdullah Al-Shammari, Emad Q. Hussein, Ameer Alaa Oleiwi
‘Material Characterization and Stress Analysis of a Through Knee
Prosthsis Sockets’ International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS, Vol. 17, No. 06, 2017.
[40] Zainab Yousif Hussien, Kadhim Kamil Resan ‘Effects of Ultraviolet
Radiation with and without Heat, on the Fatigue Behavior of Below-Knee Prosthetic Sockets’ International Journal of Mechanical and
Production Engineering Research and Development (IJMPERD), Vol.
07 , No. 06, 2017. [41] Abeer R. Abbas, Kadhim A. Hebeatir, Kadhim K. Resan ‘Effect of CO2
Laser on Some Properties of NI46TI50CU4 Shape Memory Alloy’
International Journal of Mechanical and Production Engineering Research and Development, Vol. 08, No. 02, pp. 451-460, 2018.
[42] Kadhim K. Resan, Abbas A. Alasadi, Muhannad Al-Waily, Muhsin J.
Jweeg ‘Influence of Temperature on Fatigue Life for Friction Stir Welding of Aluminum Alloy Materials, International Journal of
Mechanical & Mechatronics Engineering IJMME-IJENS, Vol. 18, No.
02, 2018.