Beruflich Dokumente
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Volume 6, Issue 11, Nov 2015, pp. 50-56, Article ID: IJMET_06_11_006
Available online at
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=6&IType=11
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
IAEME Publication
1. INTRODUCTION
Press tools are commonly used to produce components at high volumes by performing
operations like bending, shearing, deep drawing etc. The metal is pressed between
punch and die set and the article of desired shape is obtained [1].
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Elasto-Plastic Analysis of a Heavy Duty Press using F.E.M and Neubers Approximation
Methods
Sufficient clearance between punch and die needs to be provided depending on the
type of operation performed, metal used, thickness of sheet metal employed.
Otherwise, failure of punch and die occurs before the estimated design life [1, 2].
Elasto-Plastic analysis accounts for material non- linearity. After exceeding yield
strength, the rigidity of the material is different from that in the elastic range; besides,
after the yield strength is exceeded, unloading can leave deformations from the plastic
state. Note that the assumed material non- linearity does not account for the change in
material rigidity based on external factors, such as temperature. Rheological issues
(change in material properties over time) are also not evaluated [3].
Neubers method is used to convert an elastically computed stress or stain into the
real stress or strain when plastic deformation occurs. The Neubers method of finding
the elasto-plastic solution is a formula based mathematical approach b y which one can
find the elasto-plastic solution without performing the elasto-plastic analysis. This is
an approximation technique that can be used to take into account the redistribution of
stress caused by plastic flow in a zone of stress concentration [4].
3.7% 0.015%
Mg
Si
Cr
Mn
Ni
Cu
Fe
Yield
Elastic
strength modulus
169000
MPa
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The required degrees of freedom constraints (boundary conditions) and loads can
be applied to the Finite Element model in Ansys. A pressure of 90.61 MPa is applied
on the bottom face of the tool because it is the equivalent value of the pressure to the
force of 500T acting on the quarter model. When the loads and boundary conditions
are applied, the F.E.model looks as shown in Figure 5. It is solved to obtain the stress
pattern and it is shown in Figure 6.
Performing a single analysis is not be sufficient to present the converged results in
F.E.M. as the percentage difference between the SMX (maximum result value on
plot) and SMXB (result value, maximum bound estimate) in the Von-Misses Stress
plot is more than 10%. Hence it is needed to refine the mesh and resolve the problem.
Submodeling is considered to solve for the stresses. The submod el is selected so that
the three critical stress regions of the geometry are present in it and appropriate
boundary conditions with fine mesh are applied on it. After solving, Von-Misses
stress pattern is as shown in Figure 7;
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Elasto-Plastic Analysis of a Heavy Duty Press using F.E.M and Neubers Approximation
Methods
The solution is converged as the percentage difference between SMX & SMXB in
Von-Misses Stress plot is around 10%. The final results for the elastic solution of
upper tool of the press are given in Table 2.
Table 2 Elastic stresses in upper tool
Stress in Y-direction Von-Misses Stress
- 448.961 MPa
454.519 MPa
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As in the case of Elastic analysis, even here the submodel is considered with fine
mesh and appropriate boundary conditions. The stress pattern after solving the
problem in Ansys is tabulated in Table 4 [7].
Table 4 Elasto-Plastic stress pattern in upper tool at different load steps
Load Step No: Pressure Applied Stress in Y-direction Von-Misses Stress
1
50
-247.743
250.811
2
75
-325.887
318.323
3
90.61
-347.741
319.541
4
125
-378.494
337.558
For the chosen material of the tool, the values are tabulated in Table 5.
Table 5 Ramberg-Osgood equation parameters
Elastic Stress Elastic Modulus
K
n
449 MPa
169000 MPa
575 MPa 0.101
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Elasto-Plastic Analysis of a Heavy Duty Press using F.E.M and Neubers Approximation
Methods
In the above equation the %Strain values are manipulated with necessary
increments for the required number of steps. Here, the value is manipulated from
0.266 to 2 with 101 steps and get the corresponding Neubers stress values. After
getting the strain and stress values they are plotted with suitable scale on the same
graph on which the Ramberg-Osgood stress-strain curve is plotted. The point where
both the curves meet gives the Elasto-Plastic solution. The solution is tabulated in
Table 6 and the curves are shown in Figure 8.
Table 6 Results from Neubers Approximation Method
Property Measured
Result from Neubers Method
Equivalent Total Strain
0.35 %
Elastic Strain
0.18 %
Plastic Strain
0.17 %
Real (Elasto-Plastic) Stress
320 MPa
Neuber's Conversion
500
400
300
Stress
100
0
0
0.25
0.5
0.75
1.25
1.5
1.75
% Strain
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ACKNOWLEDGEMENTS
The authors express their sense of gratitude to M/S Premier Engineering Industries,
Hyderabad for the support given in the study of their press. The authors also thanks
the Director and Correspondent of Vidya Jyothi Institute of Technology, Aziz Nagar,
Hyderabad, India, for the help and support extended for this work.
REFERENCES
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
Sachin. G, Design Analysis and Overview of Press Tool with its Defects and
Remedies, International Journal of Engineering Technology, Management and
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Fissha Biruke Teshome, Design of Combined Press Tool for the Manufacturing
of Rice Thresher Blade, The International Journal of Engineering And Science
(IJES), Volume 3, Issue 4, pp 90-107.
G.R. Nagpal, Tool Engineering and Design, 2002 Khanna Publishers.
Neuber, H., Theory of Stress Concentration for Shear-Strained Prismatical Bodies
with Arbitrary Nonlinear Stress-Strain Law, ASME Journal of Applied
Mechanics 28, 1961.
Cyril Donaldson, George.H.LeCain, V.C.Goold, Tool Design 3rd edition, Tata
McGraw-Hill Education, New Delhi.
J.R. Paquin & R.E. Crowley, Die Design Fundamental, Industrial Press, 1962.
Dr. Yadavalli Basavaraj and Pavan Kumar B K. Modeling and Analysis of Base
Plate for Brake Spider Fixture by FEM using Ansys Software. International
Journal of Mechanical Engineering and Technology, 4(5), 2013, pp. 26-30.
Ramberg, W., & Osgood, W. R. (1943). Description of stressstrain curves by
three parameters. Technical Note No. 902, National Advisory Committee for
Aeronautics, Washington DC.
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