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End sem presentation 2019 -2020.pptx

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Praveen Kumar

The document is an end semester presentation by G. Praveen Kumar at BITS Pilani Hyderabad Campus about his research on experimental investigations and mathematical modeling of incremental forming processes. It includes objectives of his proposed research, results from finite element simulations of an incremental hole flanging process, graphs and figures to illustrate the simulations and results, and a list of 10 relevant references.

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BITS Pilani Hyderabad Campus End Semester Presentation: Second Semester (2019-20) Department of Mechanical Engineering Name: G. Praveen Kumar ID No. : 2016PHXF0420H Supervisor Name : Dr. K. Suresh DAC members: Dr. Pavan Kumar .P and Dr. Nitin .K
BITS Pilani Hyderabad Campus Experimental investigations and mathematical modeling of incremental forming processes
BITS Pilani, Hyderabad Campus • Objectives of the Proposed Research • Finite element simulations on hole flanging process • Results and discussions • Publications • References Contents 3
BITS Pilani, Hyderabad Campus 1. Analysis of surface roughness in parts formed by incremental forming. 2. Experimental and theoretical studies on formability in incremental forming. 3. Analysis of form accuracy, spring back and forming forces in incremental forming process. 4. Experimental investigation in incremental hole flanging process. 5. Finite element (FE) simulations of incremental forming. Objectives of the proposed research 4
BITS Pilani, Hyderabad Campus  Hole flanging produced by a single point incremental forming is a new process, in which the sheet with a pre–cut hole is progressively forced with a tool to produce cylindrical or conical smooth flanges.  It has various applications in rapid prototyping and low volume production of conical and vertical flanges in sheet metal parts. Fig. 1 Schematic representation of incremental hole-flanging process Introduction to incremental hole flanging process 5
BITS Pilani, Hyderabad Campus Finite element simulation incremental hole flanging process Fig. 2: Finite element model of incremental hole flanging process Fig. 3: Time versus Position data for (a) X, (b) Y and (c) Z ordinate 6
BITS Pilani, Hyderabad Campus  Keyword file for shell element input data contd… Finite element simulation incremental hole flanging process 7
BITS Pilani, Hyderabad Campus  Keyword file for material properties input data contd… Finite element simulation incremental hole flanging process 8
BITS Pilani, Hyderabad Campus Yield strength (Mpa) 230 Youngs modulus (Gpa) 200 Ultimate strength (Mpa) 320 % Elongation 33 Strength coefficient (Mpa) 519 Strain hardening exponent 0.18  Table1:Mechanical properties of Deep drawing steel contd… Fig. 4 Stress strain diagram Finite element simulation incremental hole flanging process 9
BITS Pilani, Hyderabad Campus 1st stage 2nd stage 3rd stage 4th stage Fig. 5 Simulations of multistage incremental hole flanging process 10 Finite element simulation incremental hole flanging process contd…
BITS Pilani, Hyderabad Campus Results anddiscussions 1.Vertical forming forces in IHF 2.Wall thickness distribution 3. Strain path evaluation 11
BITS Pilani, Hyderabad Campus 1.Vertical forming forces Results anddiscussions Fig. 6: Vertical forming forces vs time 12
BITS Pilani, Hyderabad Campus 2.Wall thickness distribution Results anddiscussions Fig. 7: Wall thickness profiles of flanges with various stages 13
BITS Pilani, Hyderabad Campus 3. Strain path evaluation Results anddiscussions Stage 1 Stage 2 Stage 3 Stage 4 Fig. 8: Simulated strain path for different stages 14
BITS Pilani, Hyderabad Campus 1. Cui, Z., Gao, L., Studies on hole flanging process using multistage incremental forming. CIRP Journal of Manufacturing Science and Technology, 2010;2:124-128. 2. Petek, A., Kuzman, K., Backward hole-flanging technology using an incremental Approach, Journal of Mechanical Engineering, 2012;58:73-80. 3. Centeno, G., Silva, M.B., Cristino, V.A.M., Vallellano, C., Martins P.A.F., Hole flanging by incremental sheet forming. International Journal of Machine tool Manufacture,2012; 59: 46-54. 4. Borrego, M., Morales - Palma, D., Martínez-Donaire, A.J., Centeno, G., Vallellano, C., Experimental study of hole-flanging by single-stage incremental sheet forming. Journal of Materials Processing Technology, 2016;237(1):320-330. 5. Cristino, V.A., Montanari, L., Silva, M.B., Atkins, A.G., Martins P.A.F., Fracture in hole-flanging by single-stage incremental sheet forming. International Journal of Mechanical Sciences, 2014;83:146-154. 6. Hussain G, Valaei H, Al-Ghamdi KA, Khan B. Finite element and experimental analyses of cylindrical hole flanging in incremental forming. Transactions of Nonferrous Metals Society of China. 2016;26(9):2419-2425. 7. Surech K, Regalla SP. Effect of time scaling and mass scaling in numerical simulation of incremental forming. InApplied Mechanics and Materials 2014 (Vol. 612, pp. 105-110). Trans Tech Publications. 8. Montanari L, Cristino VA, Silva MB, Martins PA. A new approach for deformation history of material elements in hole-flanging produced by single point incremental forming. The International Journal of Advanced Manufacturing Technology. 2013 Nov 1;69(5-8):1175-83. 9. Morales-Palma D, Borrego M, Martínez-Donaire A, Centeno G, Vallellano C. Optimization of hole-flanging by single point incremental forming in two stages. Materials. 2018 Oct;11(10):2029. 10.Martínez-Donaire AJ, Borrego M, Morales-Palma D, Centeno G, Vallellano C. Analysis of the influence of stress triaxiality on formability of hole- flanging by single-stage SPIF. International Journal of Mechanical Sciences. 2019 Feb 1;151:76-84. References 15
BITS Pilani, Hyderabad Campus International Journal: 1. Praveen, G., Ram Tarun Reddy, and Kurra Suresh. "Experimental studies on incremental hole flanging of steel sheets." Advances in Materials and Processing Technologies (2019): 1-11.(Published in Taylor and Francis) (Scopus) 2. Praveen, G., Inturi Vamsi, Kurra Suresh and Sudha radhika. “Evaluation of surface roughness in incremental forming using image processing based methods’’Journal of Measurement.(Under review) International Conference: 1. Suresh, Kurra, Praveen Kumar, Amrita Priyadarshini, and Nitin Kotkunde. "Analysis of formability in incremental forming processes." Materials Today: Proceedings(2018), 5(9),18905-18910.(Scopus) 2. Praveen, G., and Kurra Suresh “Experimental study on forming force measurement for AA 1100 sheets by incremental forming” , Materials Today: Proceedings(2019), 18(7),2738-2744.(Scopus) Publications 16
BITS Pilani Hyderabad Campus THANKYOU
BITS Pilani, Hyderabad Campus 1st stage 2nd stage 3rd stage 4th stage 11 Finite element simulation incremental hole flanging process
BITS Pilani, Hyderabad Campus
Fig. 2 (a) 1/8 scaled model of a Shinkansen bullet train (b) Ford logo using the F3T technology
Fig. 1 Applications of ISF: a inner side of a hood for Honda S800 model car [8]; b normal feature lines of TOYOTA iQ compared with sharpen feature line of TOYOTA iQ-GRMN [8]; c customised ankle support [10] d customised Buddha face (AMINO website); e sample with 4.5-mm-thickness material of hot rolled steel [8]
Fig. 3 The manufacture of an ankle support, from request, to scanning of a live subject (reverse engineering), to setting up a solid model and CAD drawing, to embedding the shape for toolpath planning, to creating a toolpath for manufacture, to checking for accuracy
Fig. 5 Prototypes for Automotive industries
Fig. 6 Non –Automotive Prototype Examples
Fig. 8 Shapes used to demonstrate the viability of the process and for experiments
Table 2 Potential applications area of AISF
End sem presentation 2019 -2020.pptx

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End sem presentation 2019 -2020.pptx

  • 1. BITS Pilani Hyderabad Campus End Semester Presentation: Second Semester (2019-20) Department of Mechanical Engineering Name: G. Praveen Kumar ID No. : 2016PHXF0420H Supervisor Name : Dr. K. Suresh DAC members: Dr. Pavan Kumar .P and Dr. Nitin .K
  • 2. BITS Pilani Hyderabad Campus Experimental investigations and mathematical modeling of incremental forming processes
  • 3. BITS Pilani, Hyderabad Campus • Objectives of the Proposed Research • Finite element simulations on hole flanging process • Results and discussions • Publications • References Contents 3
  • 4. BITS Pilani, Hyderabad Campus 1. Analysis of surface roughness in parts formed by incremental forming. 2. Experimental and theoretical studies on formability in incremental forming. 3. Analysis of form accuracy, spring back and forming forces in incremental forming process. 4. Experimental investigation in incremental hole flanging process. 5. Finite element (FE) simulations of incremental forming. Objectives of the proposed research 4
  • 5. BITS Pilani, Hyderabad Campus  Hole flanging produced by a single point incremental forming is a new process, in which the sheet with a pre–cut hole is progressively forced with a tool to produce cylindrical or conical smooth flanges.  It has various applications in rapid prototyping and low volume production of conical and vertical flanges in sheet metal parts. Fig. 1 Schematic representation of incremental hole-flanging process Introduction to incremental hole flanging process 5
  • 6. BITS Pilani, Hyderabad Campus Finite element simulation incremental hole flanging process Fig. 2: Finite element model of incremental hole flanging process Fig. 3: Time versus Position data for (a) X, (b) Y and (c) Z ordinate 6
  • 7. BITS Pilani, Hyderabad Campus  Keyword file for shell element input data contd… Finite element simulation incremental hole flanging process 7
  • 8. BITS Pilani, Hyderabad Campus  Keyword file for material properties input data contd… Finite element simulation incremental hole flanging process 8
  • 9. BITS Pilani, Hyderabad Campus Yield strength (Mpa) 230 Youngs modulus (Gpa) 200 Ultimate strength (Mpa) 320 % Elongation 33 Strength coefficient (Mpa) 519 Strain hardening exponent 0.18  Table1:Mechanical properties of Deep drawing steel contd… Fig. 4 Stress strain diagram Finite element simulation incremental hole flanging process 9
  • 10. BITS Pilani, Hyderabad Campus 1st stage 2nd stage 3rd stage 4th stage Fig. 5 Simulations of multistage incremental hole flanging process 10 Finite element simulation incremental hole flanging process contd…
  • 11. BITS Pilani, Hyderabad Campus Results anddiscussions 1.Vertical forming forces in IHF 2.Wall thickness distribution 3. Strain path evaluation 11
  • 12. BITS Pilani, Hyderabad Campus 1.Vertical forming forces Results anddiscussions Fig. 6: Vertical forming forces vs time 12
  • 13. BITS Pilani, Hyderabad Campus 2.Wall thickness distribution Results anddiscussions Fig. 7: Wall thickness profiles of flanges with various stages 13
  • 14. BITS Pilani, Hyderabad Campus 3. Strain path evaluation Results anddiscussions Stage 1 Stage 2 Stage 3 Stage 4 Fig. 8: Simulated strain path for different stages 14
  • 15. BITS Pilani, Hyderabad Campus 1. Cui, Z., Gao, L., Studies on hole flanging process using multistage incremental forming. CIRP Journal of Manufacturing Science and Technology, 2010;2:124-128. 2. Petek, A., Kuzman, K., Backward hole-flanging technology using an incremental Approach, Journal of Mechanical Engineering, 2012;58:73-80. 3. Centeno, G., Silva, M.B., Cristino, V.A.M., Vallellano, C., Martins P.A.F., Hole flanging by incremental sheet forming. International Journal of Machine tool Manufacture,2012; 59: 46-54. 4. Borrego, M., Morales - Palma, D., Martínez-Donaire, A.J., Centeno, G., Vallellano, C., Experimental study of hole-flanging by single-stage incremental sheet forming. Journal of Materials Processing Technology, 2016;237(1):320-330. 5. Cristino, V.A., Montanari, L., Silva, M.B., Atkins, A.G., Martins P.A.F., Fracture in hole-flanging by single-stage incremental sheet forming. International Journal of Mechanical Sciences, 2014;83:146-154. 6. Hussain G, Valaei H, Al-Ghamdi KA, Khan B. Finite element and experimental analyses of cylindrical hole flanging in incremental forming. Transactions of Nonferrous Metals Society of China. 2016;26(9):2419-2425. 7. Surech K, Regalla SP. Effect of time scaling and mass scaling in numerical simulation of incremental forming. InApplied Mechanics and Materials 2014 (Vol. 612, pp. 105-110). Trans Tech Publications. 8. Montanari L, Cristino VA, Silva MB, Martins PA. A new approach for deformation history of material elements in hole-flanging produced by single point incremental forming. The International Journal of Advanced Manufacturing Technology. 2013 Nov 1;69(5-8):1175-83. 9. Morales-Palma D, Borrego M, Martínez-Donaire A, Centeno G, Vallellano C. Optimization of hole-flanging by single point incremental forming in two stages. Materials. 2018 Oct;11(10):2029. 10.Martínez-Donaire AJ, Borrego M, Morales-Palma D, Centeno G, Vallellano C. Analysis of the influence of stress triaxiality on formability of hole- flanging by single-stage SPIF. International Journal of Mechanical Sciences. 2019 Feb 1;151:76-84. References 15
  • 16. BITS Pilani, Hyderabad Campus International Journal: 1. Praveen, G., Ram Tarun Reddy, and Kurra Suresh. "Experimental studies on incremental hole flanging of steel sheets." Advances in Materials and Processing Technologies (2019): 1-11.(Published in Taylor and Francis) (Scopus) 2. Praveen, G., Inturi Vamsi, Kurra Suresh and Sudha radhika. “Evaluation of surface roughness in incremental forming using image processing based methods’’Journal of Measurement.(Under review) International Conference: 1. Suresh, Kurra, Praveen Kumar, Amrita Priyadarshini, and Nitin Kotkunde. "Analysis of formability in incremental forming processes." Materials Today: Proceedings(2018), 5(9),18905-18910.(Scopus) 2. Praveen, G., and Kurra Suresh “Experimental study on forming force measurement for AA 1100 sheets by incremental forming” , Materials Today: Proceedings(2019), 18(7),2738-2744.(Scopus) Publications 16
  • 18. BITS Pilani, Hyderabad Campus 1st stage 2nd stage 3rd stage 4th stage 11 Finite element simulation incremental hole flanging process
  • 20. Fig. 2 (a) 1/8 scaled model of a Shinkansen bullet train (b) Ford logo using the F3T technology
  • 21. Fig. 1 Applications of ISF: a inner side of a hood for Honda S800 model car [8]; b normal feature lines of TOYOTA iQ compared with sharpen feature line of TOYOTA iQ-GRMN [8]; c customised ankle support [10] d customised Buddha face (AMINO website); e sample with 4.5-mm-thickness material of hot rolled steel [8]
  • 22. Fig. 3 The manufacture of an ankle support, from request, to scanning of a live subject (reverse engineering), to setting up a solid model and CAD drawing, to embedding the shape for toolpath planning, to creating a toolpath for manufacture, to checking for accuracy
  • 23. Fig. 5 Prototypes for Automotive industries
  • 24. Fig. 6 Non –Automotive Prototype Examples
  • 25. Fig. 8 Shapes used to demonstrate the viability of the process and for experiments
  • 26. Table 2 Potential applications area of AISF