Metal forming Modelling and Experiments

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METAL FORMING MODELLING AND EXPERIMENTS The objective of this research proposal is the development of a high tech heat assisted spinning process for hard-to-shape high strength materials through a combination of experiments and efficient numerical simulations of this complex metal forming process. Sheet-metal spinning is an effective method for transforming flat sheet metal into hollow shapes, usually with axisymmetric profiles. The method uses a tool i.e. a roller which forces a metal blank onto a revolving mandrel. The roller is pressed against the blank and is moved axially into complex trajectories to achieve finally a hollow-shaped product. To obtain the right shape at the lowest possible manufacturing cost, experiments will be conducted to characterize the base materials’ properties. These properties will be used to build an efficient finite element model of the process, including the heating strategy which will be first directly linked to the roller displacement and will be later separately controlled in displacement. Through real cold and hot spinning experiments a valuable database will be built and used for validation of non-linear dynamic finite element simulations. The goal is to bring the conventional spinning process to a new technological level by adding high tech heating sources (like laser heating) in the forming steps of hard to shape high strength materials, keeping material properties, acceptable surface state and maintaining the heat assisted spinning operation at the lowest cost as possible.