Effects of geometry and fillet radius on die stresses in stamping processes.pdf

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Effects of geometry and fillet radius on die stresses in stamping processes.pdf

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Effects of geometry and fillet radius on die stresses in stamping processes

Effects of geometry and ?llet radius on die stresses in stamping processes J.S. Sun, K.H. Lee*, H.P. Lee Department of Mechanical and Production Engineering, National University of Singapore, 10 Kent Ridge Crescent, Singapore 119260, Singapore Received 23 February 1999 Abstract This paper describes the use of the ?nite element method to analyze the failure of dies in stamping processes. For the die analyzed in the present problem, the cracks at different locations can be attributed to a couple of mechanisms. One of them is due to large principal stresses and the other one is due to large shear stresses. A three-dimensional model is used to simulate these problems ?rst. The model is then simpli?ed to an axisymmetric problem for analyzing the effects of geometry and ?llet radius on die stresses. # 2000 Elsevier Science S.A. All rights reserved. Keywords: Stamping; Metal forming; Finite element method; Die failure 1. Introduction In metal forming processes, die failure analysis is one of the most important problems. Before the beginning of this decade, most research focused on the development of the- oretical and numerical methods. Upper bound techniques [1,2], contact-impact procedures [3] and the ?nite element method (FEM) [4,5] are the main techniques for analyzing stamping problems. With the development of computer technology, the FEM becomes the dominant technique [6±12]. Altan and co-workers [13,14] discussed the causes of failure in forging tooling and presented a fatigue analysis concept that can be applied during process and tool design to analyze the stresses in tools. In these two papers, they used the punching load as the boundary force to analyze the stress states that exist in the inserts during the forming process and determined the causes of the failures. Based on these con- cepts, they also gave some suggestions to improve die design. In this paper, linear stress analysis of a three-dimensional (3D) die model is presented. The stress patterns are then