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Simulation and Evaluation of Models for a Pre In-Die Cutting and an In-Die Cutting Process
Umeå University, Faculty of Science and Technology, Department of Physics.
2015 (English)Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

Pre in-die and in-die cutting are processes coupled to metal forming operations. The aim of the thesis was to find, develop, evaluate and validate simulation models for these processes. The goal for pre in-die cutting model was to split a shell segment into multiple segments and for the in-die cutting model to predict cutting tool forces. All models were also supposed to produce physically correct animations. The simulations were made in LS-DYNA and prepared and analyzed in the pre/postprocessor, LS-PrePost. Three simulation models were developed for pre in-die cutting. All with the possibility to split a metal sheet into multiple parts and produce animations of the results. Two models were developed for in-die cutting, the first model uses only shell elements, whereas the other also uses solid elements to represent the metal sheet. The segments essential for the models functionality and how to use them are described in the thesis. Parameter studies were also performed to the evaluate the effects of different variables in the solid model. It was found that many parameters affect the contact stability, dynamic behaviour and cutting tool forces. The information from these studies was used to find an optimal parameter set that was used to correlate the model to experiments. The model was then able to produce results with good correlation to current experiments and to produce physically correct animations. However the experimental data is limited and further experiments need to be carried out to validate the model for more general cases. Finally a method to connect the in-die cutting model to current forming simulations was developed, described and demonstrated.

Place, publisher, year, edition, pages
Keyword [en]
Pre in-die cutting, In-die cutting, Metal forming operations, Simulation models, Finite element methods (FEM), LS-DYNA
National Category
Applied Mechanics
URN: urn:nbn:se:umu:diva-111959OAI: diva2:874453
Subject / course
Examensarbete i teknisk fysik
Educational program
Master of Science Programme in Engineering Physics
2015-11-13, Universitetsklubben, Universums gränd, Umeå, 10:00 (Swedish)
Available from: 2015-11-27 Created: 2015-11-26 Last updated: 2015-11-27Bibliographically approved

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