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• W2948987574 abstract "Sheet Metal Forming is used in major manufacturing like Automotive and Aerospaceindustries for producing various parts. Materials with low forming limit and highspringback cannot be formed using this process without inducing failure and geomet-rical inaccuracies into the parts. Whereas materials with higher formability can bedeformed to a larger extent before failure as compared to lower formability materials.The elastic recovery of the sheet metal after the forming process commonly knownas springback which causes geometrical inaccuracies. Materials like Ti-alloys, withhigher strength possess low formability and higher springback but also they provideadvantage of higher strength to weight ratio over ferrous alloys. Many researchers aretrying to develop new forming techniques to form these materials.A new approach to improve formability and reduce springback of materials usingelectrical current has been studied and is found to provide greater advantage over theconventional sheet metal forming processes. Reduction in flow stress due to electriccurrent flow during deformation process is defined as Electroplastic Effect. This effectis related to the interaction between flowing electrons and moving dislocations. It wasobserved that decrease in force required for plastic deformation is directly proportionalto the difference between drift speed (electron flow speed in particular material) anddislocation motion speed.Sheet metal bending experiments are conducted and the effect of electric currenton springback is observed. To conduct bending experiments bend fixture is designed.Proper electrical insulation is included in design to ensure safe operation and to pre-vent electric flow in machine. Material selection is done on the basis of maximumstress developed in deformable tool and die in Finite Element Analysis results. Mate-rial is selected in such a way that the yield strength (including factor of safety ’3’) ofthe material must always be greater than produced maximum stress in FE analysis.After finalizing design and material for each part of the bend fixture, fabrication isdone.FE analysis is carried out for sheet metal bending process and results are comparedwith published results to validate FE model. After validation, FE model is used withprovided material (HSQ steel) properties to compare simulation and experimentalresults. It is observed that FE model is predicting springback close to experimentalresults.Sheet metal bending experiments on HSQ (High Strength Quenched) steel (pro-vided by TATA Steel) are performed. Electric current, pulse frequency, duty cycle,tool radius, feed rate and dwell time are considered as factors for electroplasticityexperiments. Full factorial design of experiments with 2-levels is carried out to seecomplete effect. Total 64 experiments are carried out to analyse complete design ofexperiments. Whole sheet bending process is recorded using a digital camera. Fromrecorded video, images are extracted at the end of deformation and after unloading.For springback measurement, radius of curvature in bend region is calculated usingpoints traced from both the images and the difference between radius of curvaturebefore unloading and after unloading is defined as springback. This methodology isused to eliminate the error induced due to initial curvature present in sheet speci-mens. Because of initial curvature, it is observed that measuring bend angle afterspringback is not accurate method.It is observed from electroplastic bending experiments that springback and punchforce are decreased compared to conventional bending process. From DOE analysis itis concluded that the parameters which are affecting springback are mainly current,pulse frequency and tool radius. Temperature measurement is also carried out andmaximum temperature reached during each experiment are noted down. It is con-cluded that increase in temperature (200o C) is not significant enough to cause anychange in grain structure levels." @default.
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• W2948987574 date "2017-01-01" @default.
• W2948987574 modified "2023-09-27" @default.
• W2948987574 title "Electric Pulse Aided Bending: An Experimental Study" @default.
• W2948987574 hasPublicationYear "2017" @default.
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