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Abstract(s)
Os processos de conformação plástica permitem uma elevada cadência produtiva
na obtenção de peças complexas, sem necessidade de posteriores operações de finalização
de peça. A capacidade de dar forma a uma chapa metálica plana requer uma tecnologia
própria baseada no conceito de plasticidade, onde se destaca a estampagem. De um modo
geral, no processo de estampagem, a chapa é progressivamente sujeita a várias operações
de conformação plástica por ação de uma força externa, a fim de se obter a forma final
desejada.
Em virtude da grande competitividade no setor automóvel, a tendência atual nos
processos de conformação plástica cursa na introdução de produtos com geometrias
complexas e utilização de materiais cada vez mais leves e resistentes. Como tal, o intuito
será reduzir o ciclo de desenvolvimento das ferramentas de estampagem, sem recorrer a
dispendiosos ciclos de tentativa/ erro. Desta forma, a previsão do processo, com o auxílio
da simulação numérica baseada no método dos elementos finitos, é parte integrante e
imprescindível no dimensionamento das ferramentas de estampagem.
As principais dificuldades na produção de peças estampadas relacionam-se com a
previsão do comportamento da chapa ao longo do processo. Os defeitos na forma, na
superfície ou nas propriedades mecânicas da peça, exigem uma fase de projeto rigorosa.
Este trabalho teve como objetivo a validação do processo de estampagem de um
componente de chapa metálica automóvel, através da simulação numérica baseada no
cálculo do método dos elementos finitos. Para tal, foi estudado o comportamento da
chapa, definido o ciclo de estampagem, compensada a recuperação elástica, otimizado o
processo, analisada a capacidade do processo e comparados os resultados numéricos com
os experimentais.
ABSTRACT: Sheet metal forming processes allow a high production rate, obtaining complex parts without the need of subsequent finishing operations. The ability to give shape to a flat metal sheet in based on the concept of plasticity. In general, the sheet is progressively subjected to various forming operations in order to obtain the desired final shape, using external forces through the forming tools. Due to the high competitiveness in the automotive sector, the current trend in sheet metal forming processes is towards to the introduction of complex geometry products, reduction of development cycle and the use of increasingly stronger and lighter materials. Hence, the actual objective is to reduce the development cycle of the stamping tools, without resorting to expensive trial and error analysis. Therefore, the numerical simulation of the forming process based on the finite element method is an integral and indispensable part in the design of the stamping tools. The main difficulties in the production of stamped parts are related to the prediction of the sheet metal behaviour throughout the process. Shape defects, surface defects and the mechanical performance of the final components require a rigorous design stage. This study aims to validate the stamping process of a metallic automotive component through numerical simulation. The sheet metal forming process was studied by numerical simulation, defining all forming/trimming stages, as well as the compensation of the springback. Therefore, the process was optimised, comparing numerical and experimental results.
ABSTRACT: Sheet metal forming processes allow a high production rate, obtaining complex parts without the need of subsequent finishing operations. The ability to give shape to a flat metal sheet in based on the concept of plasticity. In general, the sheet is progressively subjected to various forming operations in order to obtain the desired final shape, using external forces through the forming tools. Due to the high competitiveness in the automotive sector, the current trend in sheet metal forming processes is towards to the introduction of complex geometry products, reduction of development cycle and the use of increasingly stronger and lighter materials. Hence, the actual objective is to reduce the development cycle of the stamping tools, without resorting to expensive trial and error analysis. Therefore, the numerical simulation of the forming process based on the finite element method is an integral and indispensable part in the design of the stamping tools. The main difficulties in the production of stamped parts are related to the prediction of the sheet metal behaviour throughout the process. Shape defects, surface defects and the mechanical performance of the final components require a rigorous design stage. This study aims to validate the stamping process of a metallic automotive component through numerical simulation. The sheet metal forming process was studied by numerical simulation, defining all forming/trimming stages, as well as the compensation of the springback. Therefore, the process was optimised, comparing numerical and experimental results.
Description
Keywords
Conformação de chapa metálica Simulação numérica Formabilidade da chapa Recuperação elástica AutoForm CATIA