Modeling and Machining of Sheet Metal Dies and Inspection Fixtures.

International Research Journal of Engineering and Technology (IRJET)

e-ISSN: 2395 -0056

Volume: 04 Issue: 07 | July -2017

p-ISSN: 2395-0072

www.irjet.net

Modeling And Machining Of Sheet Metal Dies And Inspection Fixtures R. SATYA MAHIPAL REDDY1, P. SREELATHA2, Y. AKSHAY KUMAR3 1,2 Assistant

Professor, Dep. Of Mechanical Engg, Geethanjali college Of engg. and Technology. Professor, Dep. Of Mechanical Engg, CVSR college of engineering Hyderabad, India. ---------------------------------------------------------------------***--------------------------------------------------------------------3Assistant

Abstract - Extrusion is a metal forming process, In this process the material is pushed or drawn through a die of desired cross-section to create long object of a fixed cross-section area, extrusion may be continuous ( producing infinitely long material ) or semi continuous (producing many pieces). The extrusion process can be done with the material hot or cold. There is gradual deformation which results in the uniform microstructure. Anon-linear converging cosine dies profiles are used for square to square extrusion process. Extrusion through mathematically contoured die plays a critical role in improvement of surface finish of extruded product. The cosine die profile designed using CATIA, Solid works and MATLAB was used to find out the coordinate of the cosine die profile and solid model was generated using CATIA the STL files of extrusion dies generated by solid work and CATIA. The STL files are used in DEFORM-3D Software for FEM simulation. The work piece, punch and container with cosine die profiles are used in DEFORM-3D software for simulation purpose. Extrusion was assumed to be isothermal condition, for extrusion purpose Al- 6062 work material are used in DEFORM-3D Software. FEM modeling determine damage Strain-effective (mm/mm), strain rate-effective ((mm/mm)/sec), stress- effective (M Pa), stress-Max principal (M Pa), Velocity Total V el (mm/sec) and Temperature (C0). The results optioned during FEM simulation of Al6062[FEA] are compared with the FEM simulation results of Tellurium Led [FEA]. For Extrusion process of Al-6062, the Extrusion load and pressure are more as compared to extrusion of Tellurium Lead under same percentage of Reductions and comparisons of load and pressure between Aluminum and Tellurium Lead during deformation process. 1. INTRODUCTION

Forming is the processes in which the wanted shape and size are achieved through the plastic deformation of a material .The stressed induced during forming process are greater than the yield strength, But less than the fracture strength of the material. Metal Forming operations such as forging, Rolling, Drawing etc. are capable of yielding high productivity compare to other metal working techniques. Metal forming is one of the most important process in manufacturing of a large variety of products. Metal Š 2017, IRJET

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forming or metal working process is divided into two parts; Bulk forming and sheet metal forming. The Bulk forming refers to processes like Forging, Rolling Extrusion etc. where there is a controlled plastic flow of material into required shapes. Forming process can be divided into three categories. Cold Working < 0.4 Tm Warm Working 0.4 - 0.6 Tm Hot Working > 0.6 Tm Where Tm is melting point of material (K) Slab method of analysis: This method assumes that the metal deforms homogeneously in the deformation zone. A square lattice placed in the deformation zone would be inaccurate into four-sided elements. It is the easiest method and widely used in strength of material. It calculates the in homogeneity due to friction but neglects the in homogeneity due to friction at the die-work piece interface and also the influence of transverse stress. It calculates the average forming stress from the work of plastic deformation. Slip line field theory: This method adopts or assumes the no homogeneous deformation and it is based on the element that any general state of stress in plain strain consists of pure shear plus a hydrostatic pressure. Slip line is in element of two [29] dimensional vector diagram, which shows the deviation of maximum shear stress identified with the direction of slip at any point. Slip line is always a network of lines passing through each other at right angle .It is made up by trial and error method. Lower bound solution The power of deformation calculated from statistically admissible field which satisfies the Stress equilibrium and yield criterion is always lower than the actual one, it is called lower bound solutions. Lower bound solutions are those, which provide values for the total power, which are lower than the actual one. Here the first step is the design of a stress tensor, which is far more difficult to look on. It is more complex to examine, so less work has been achieved. For lower bound, the requirements are more stress free and the following conditions are not necessarily fulfilled. No need to maintain compatibility, No need to satisfy stress strain relation and Geometrical boundary condition don’t have to be satisfied thus, only equation of equilibrium, yield criterion and

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