effect of blank holder force and punch number on the forming...

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International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:18 No:04 56 I J E N S August 2018 IJENS IJENS © - IJMME - 6969 - 4 0 1803 Effect of Blank Holder Force and Punch Number on the Forming Behavior of Conventional Dies Ragad Aziz Neama 1 , Maher A.R. Sadiq Al-Baghdadi 2 , Muhannad Al-Waily 3 1 University of Kufa, Faculty of Engineering, Mechanical Engineering Department, Iraq, [email protected] 2 University of Kufa, Faculty of Engineering, Mechanical Engineering Department, Iraq, [email protected] 3 University of Kufa, Faculty of Engineering, Mechanical Engineering Department, Iraq, [email protected] AbstractThe 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 TermMulti 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) = ∑ P i N i,k n i=0 (t) (1) Wherever P i , represent the control point and the number of its respectively. N i,k is the B-spline basis function which have two mathematical definitions, 1. When = 1, ,1 () = { 1 ≤< +1 0 ℎ (2) 2. When > 1, , () = ( ( +−1 ) ,−1 () + ( + + +1 ) +1,−1 () ) (3) The knot in open uniform B-spline curve requires three condition, [7], = 0 < = − + 1 ≤ ≤ = − + 2 > } 0≤≤+k (4) The basis function with ==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.

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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

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.

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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.

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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

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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

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(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.

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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.

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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

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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.

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