Mechanical Engineering, HCE College of Engineering.
Analytical treatment using the plasticity theory for the punching of sheet materials, gives insight for the total deformation load. And in order to understand the load and strain involved in such an elastic-plastic deformation, calculation of stresses in the various zones of the sheet material being formed are to be known. Such computations enable design engineers to arrive at appropriate tooling and machinery for the process. While, a simulation of the load-strain characteristics for different sheet materials facilitates the selection, by pointing the position of peak load, the data obtained cannot be designated as precise. This calls for finite element methods application to curves, surfaces as well as solids. Since, the position of peak load is important for the selection of mechanical pressesμ with optimal crank angle rotation, the design, which is modeled and simulated, must also be optimized. Some important input parameters would consist of radius of the die that is used, punch nose diameter, blank holder pressure, friction coefficient of the lubricant that is used, thickness/diameter, strength coefficient and strain hardening exponent of the material. The output that is needed is the optimized punch load, and the crank angle (designed based on the maximum load location with respect to percentage displacement).
