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prediction of Springback in Long Channels

Acta Metallurgica Sinica(English Letters) 2015年第12期28卷 1525-1531页

作者： chetan p.nikhare Mechanical Engineering Penn State Behrend

Sheet metal forming is one of the most preferred manufacturing processes in automotive and aerospace industries. However, due to increase in fuel prices and more stringent environmental regulation, these industries are facing many challenges to meet the criteria. Due to this, many efforts in design and manufacturing were considered and *** efforts were implementing lighter-weight materials like aluminum and magnesium（but they have higher elasticity as compared to steel） and implementing higher-strength steel with lower thickness. The main challenge found in both cases is springback after deformation. Springback is the elastic recovery after the part is unloaded. In this paper, the 3D channels with large length were deformed numerically and springback at different section was predicted. For this purpose, tailorwelded blank was considered. The geometric change along the long axis was also discussed. In addition, the effect of flange springback on wall springback was also analyzed. It was found that different section produced different springback and greater influence of flange springback. To validate the numerical simulation approach, the experiments on one case were performed and compared.

关键词： Channel forming Springback Numerical simulation Tailor-welded blanks

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A Numerical Approach on Reduction of Young’s Modulus During Deformation of Sheet Metals

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Modeling and Numerical Simulation of Material Science 2012年第1期2卷 1-13页

作者： chetan nikhare Mechanical Engineering Department University of New Hampshire

The paper investigates the elastic behavior of the metal after unloading. For this purpose the strip of metal with tensile gauge length was simulated with high and low strength material. Further the channel forming was modeled for combination of materials to predict the spring-back and compared the results. It is observed that the Young’s modulus (E-value) decreases with the increase in plastic strain. The strength of the material has no effect on the decrease in the E-value after unloading during tension test. However in channel forming the E-value after unloading depends on the starting E-value, spring-back angle and maximum strain achieved in the channel. The proposed mathematical equations to determine the E-value after unloading from the tension test and channel forming test gives very good prediction with each other. It is also found that the lowest spring-back occurred in the channel with the composite Hard-Soft material.

关键词： Elasticity Spring-Back Channel Forming Optimization Deformation

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pressurization System in Low pressure Tube Hydroforming

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Modeling and Numerical Simulation of Material Science 2013年第3期3卷 71-78页

作者： chetan nikhare Mechanical Engineering Department The Pennsylvania State University Erie USA

Advanced high strength steels are the group of material with high strength and good formability, because high strength lesser gauge thickness can be used without compromising the function of component. In terms of economic forming process, hydroforming is the manufacturing option which uses a fluid medium to form a component by using high internal pressure. This process gained steep interest in the automotive and aerospace industries because of its many advantages such as part consolidation, good quality of the formed part etc. The main advantage is that the uniform pressure can be transferred to whole projected part at the same time. Low pressure tube hydroforming considered an inexpensive option for forming these advanced high strength steel. This paper investigates the pressurization system used during the low pressure tube hydroforming cycle. It is observed that the usage of ramp pressure cycle during forming the part from low pressure tube hydroforming results in lesser die holding force. Also, the stress, strain and thickness distribution of the part during low pressure tube hydroforming are critically analysed.

关键词： pressure Low pressure Tube Hydroforming Ramp pressure Constant pressure Advanced High Strength Steels

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parallel Deformation of the Metals

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Modeling and Numerical Simulation of Material Science 2013年第3期3卷 79-83页

作者： chetan nikhare Mechanical Engineering Department The Pennsylvania State University Erie USA

The metal goes into the plastic deformation after the application of external load. Most of the metal forming industries work on this principle of plastic deformation. Thus the understanding of plastic deformation in the metal forming industry is important. The research on the single material plastic deformation has been carried out from many centuries before the era of Tresca. In this study the two metals 0.05% C steel annealed (soft metal) and 0.6% C steel quenched and tempered (hard metal) were deformed plastically in the parallel combination in the composite form. This study has been carried out with simple mathematical theory and simulated numerical model. The comparison shows the exact match between the mathematical and numerical results. It is also observed that the individual metal thickness affects the deformation flow curve.

关键词： plasticity Bi-Metal Metal Forming Mathematical Model Numerical Model

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prediction of fracture limits of Ni-Cr based alloy under warm forming condition using ductile damage models and numerical method

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Transactions of Nonferrous Metals Society of China 2021年第8期31卷 2372-2387页

作者： Ayush MORCHHALE Anand BADRISH Nitin KOTKUNDE Swadesh Kumar SINGH Navneet KHANNA Ambuj SAXENA chetan nikhare Department of Mechanical Engineering Birla Institute of Technology and Science-PilaniHyderabad CampusHyderabadIndia Mechanical Engineering Department Gokaraju Rangaraju Institute of Engineering and TechnologyHyderabadIndia Advanced Manufacturing Laboratory Institute of Infrastructure Technology Research and Management(IITRAM)AhmadabadIndia Department of Mechanical Engineering G.L.Bajaj Institute of Technology and ManagementGreater NoidaIndia Mechanical Engineering Department the Pennsylvania State UniversityEriePAUnited States

The stretch forming and the deep-drawing processes were carried out at 300 and 673 K to determine the safe forming and fracture limits of IN625 *** experimentally obtained strain-based fracture forming limit diagram(FFLD)was transformed into a stress-based(σ-FFLD)and effective plastic strain(EpS)vs triaxiality(η)plot to remove the excess dependency of fracture limits over the *** the prediction of fracture limits,seven different damage models were *** Oh model displayed the best ability to predict the fracture locus with the least absolute *** the experimentally obtained fracture limits have only been used for the numerical analysis,none of the considered damage models predicted the fracture strains over the entire considered range of stress triaxiality(0.33p drawing process window helped to determine wrinkling,safe and fracture zones while drawing the cylindrical cups under different temperature and lubricating ***,the highest drawing ratio of 2 was achieved at 673 K under the lubricating *** the numerically predicted results of both stretch forming and deep drawing processes using the Hill 1948 anisotropic yielding function were found to be good within the acceptable range of error.

关键词： IN625 alloy warm forming ductile damage models formability forming limit diagram deep drawing processing window finite element analysis

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