Investigation of the Stamping Process of The Jack Bracket of The Kia Rio Car
الموضوعات :Peyman Mashhadi Keshtiban 1 , Ali Fata 2
1 - Faculty of Mechanical Engineering, Urmia University of Technology, Urmia, Iran
2 - Department of Mechanical Engineering, Faculty of Engineering, University of Hormozgan, Bandar Abbas, Iran
الکلمات المفتاحية: Stamping, FEM, DOE, Box-Behnken,
ملخص المقالة :
Sheet metal forming is one of the main processes of forming thin-walled plates to produce the semi-final and final parts with high precision. In the present work, a complete investigation of the forming operation of the jack bracket of the Kia Rio car has been conducted with the help of the Design of Experiment (DOE) method, numerical simulations, and experimental investigations. First, the Finite Element (FE) method performed a numerical simulation of the process, and the results were compared with experimental results. Then, 13 proposed simulations were performed through the Box-Behnken experimental design method to study the effect of process parameters. The Friction Coefficient (FC), the press speed, and the Blank Holder Force (BHF) were chosen as input parameters. The maximum strain, the maximum stress of the part and the maximum punch force were considered output parameters. The results indicated that punch speed had the most significant effect on the plastic strain, with a contribution of 61.63%, and also FC had the most impact on the maximum force, with a contribution of 58.69%. Moreover, the role of BHF in the mentioned outputs was not considerable, but it was significant (31.47%) in the investigation of stresses.
[1] Hashemian, S., Keshtiban, P. M. and Oskui, A. 2022. Fracture Behavior of the Forged Aluminum 7075-T6 Alloy under Mixed-Mode Loading Conditions. Engineering Failure Analysis. 140: 106610. doi: 10.1016/j.engfailanal.2022.106610.
[2] Hashemian, S., Keshtiban, P.M. and Oskui, A. 2022. Numerical Simulation of Hot Forging Process of KIA Car Brake's Output Shaft. ADMT Journal. 15(1): 115-124. doi: 10.30486/admt.2022.1933346.1290.
[3] Alimirzaloo, V., Biglari, F. R., Sadeghi, M. H. et al. 2019. A Novel Method for Preform Die Design in Forging Process of an Airfoil Blade based on Lagrange Interpolation and Meta-heuristic Algorithm. International Journal of Advanced Manufacturing Technology. 102(9): 4031-4045. doi: 10.1007/s00170-019-03512-9.
[4] Taghavi, V., Alimirzaloo, V., Soleimanpur, M., et al. 2020. An Investigation of the Effective Factors in the Shape Rolling Process of a Compressor Blade. Iranian Journal of Materials Forming. 7(2):16-25. doi: 10.22099/ijmf.2020.37104.1156.
[5] Keshtiban, P. M., Taher, A. and Keshtiban, M. M. 2021. Practical Study and Finite Element Simulation of Production Process of the Bush of Gearbox of Mercedes-Benz 10-wheel Truck by Closed Die Forging. Journal of Computational Applied Mechanics. 52(1): 69-84. doi: 10.22059/jcamech.2020.312296.568.
[6] Keshtiban, P. M., Behnagh, R. and Alimirzaloo, V. 2018. Routes Investigation in Equal Channel Multi-angular Pressing Process of UFG Al− 3% Mg Alloy Strips. Transactions of the Indian Institute of Metals. 71(3): 659-664. doi: 10.1007/s12666-017-1198-3.
[7] Hein, P. 2005. A Global Approach of the Finite Element Simulation of Hot Stamping. Advanced Materials Research. 6: 763-770. doi: 10.4028/www.scientific.net/AMR.6-8.763.
[8] Firat, M. 2007. Computer Aided Analysis and Design of Sheet Metal Forming Processes: Part I–The Finite Element Modeling Concepts. Materials & Design. 28(4): 1298-1303. doi: 10.1016/j.matdes.2006.01.026.
[9] Zhang, P., Zhu, L., Luo, S. et al. 2019. Hot Stamping Forming and Finite Element Simulation of USIBOR1500 High-Strength Steel. The International Journal of Advanced Manufacturing Technology. 103(5): 3187-3197. doi: 10.1007/s00170-019-03727-w.
[10] Keshtiban, P. M. and Bashirzadeh, F. 2022. Constitutive Analysis and Hot Deformation Behavior of Homogenized Al-3Mg Alloy. JOM. 75: 905-913. doi: 10.1007/s11837-022-05648-8.
[11] Kim, K. J. 2021. Lightweight Design and Fatigue Characteristics of Automotive Knuckle by Using Finite Element Analysis. Journal of Mechanical Science and Technology. 35(7): 2989-2995. doi: 10.1007/s12206-021-0622-0.
[12] Zhou, J., Yang, X-ming et al. 2021. Numerical Simulation and Experimental Investigation of Tailored Hot Stamping of Boron Steel by Partial Heating. Journal of Materials Research and Technology. 14: 1347-1365. doi: 10.1016/J.JMRT.2021.07.025.
[13] Wang, H., Chen, G., Zhu, Q. et al. 2024. Frictional Behavior of Pure Titanium Thin Sheet in Stamping Process: Experiments and Modeling. Tribology International. 191: 109131. doi: 10.1016/j.triboint.2023.109131.
[14] Modanloo, V., Mashayekhi, A. and Akhoundi, B. 2024. A Comparative Analysis of Predictive Models for Estimating the Formability of Stamped Titanium Bipolar Plates for Proton Exchange Membrane Fuel Cells. International Journal of Hydrogen Energy. 56: 894-902. doi: 10.1016/j.ijhydene.2023.12.242.
[15] Dhinesh, K., SubhaSankari, T., Paneerselvam, T. et al. 2019. Simulation and Numerical Analysis of Warm Stamping (AA6061). Materials Today: Proceedings. 16: 598-603. doi: 10.1016/j.matpr.2019.05.134.
[16] Silva, M. B., Baptista, R. and Martins, P. 2004. Stamping of Automotive Components: a Numerical and Experimental Investigation. Journal of Materials Processing Technology. 155: 1489-1496. doi: 10.1016/J.JMATPROTEC.2004.04.208.
[17] Bidgoli, M. O., Kashyzadeh, K. R., Rahimian Koloor, S. S. et al. 2020. Optimum Design of Sunken Reinforced Enclosures under Buckling Condition. Applied Sciences, 2020. 10(23): 8449. doi: 10.3390/app10238449.
[18] Eghbalian, M., Ansari, R., Bidgoli, M. O. et al. 2022. Finite Element Investigation of the Geometrical Parameters of Waviness Carbon Nanotube on Directional Young's and Shear Elastic Modulus of Polymer Nanocomposites. Journal of The Institution of Engineers (India): Series D: 1-14. doi: 10.1007/s40033-022-00414-1.
[19] Naeini, M. M., Moghadasi, S. M. and Bidgoli, M. O. 2018. A Numerical Analysis of Reinforced T Shaped Concrete Beams by Polymeric Strap of CFRP and GFRP with Finite Element Method Technique. Civil Engineering Journal. 4(5): 1006-1018. doi: 10.28991/CEJ-0309152.
[20] Zhang, Q. , Zhang, S. and Li. J. 2017. Three Dimensional Finite Element Simulation of Cutting Forces and Cutting Temperature in Hard Milling of AISI H13 Steel. Procedia Manufacturing. 10: 37-47. doi: 10.1016/j.promfg.2017.07.018
[21] Öztürk, G. 2010. Numerical and Experimental Investigation of Perforation of ST-37 Steel Plates by Oblique Impact. 2010, Middle East Technical University. Msc thesis.
[22] Hasanzadeh, H., Mohtarami, E., Bidgoli, M. O. et al. 2022. Collapse Analysis of Al 6061 Alloy Conical Shells with Circular Cutouts under Axial Loading: Experiment and Simulation. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 236(4): 704-714. doi: 10.1177/14644207211054655
[23] Shang, J. and Daehn, J. 2011. Electromagnetically Assisted Sheet Metal Stamping. Journal of Materials Processing Technology. 211(5): 868-874. doi: 10.1016/j.jmatprotec.2010.03.005.
