ROLE OF CFD IN SHEET METAL FORMING

Abstract

CFD is maintained major role in sheet metal forming processes through hydraulic fluids. Computational fluid dynamics (CFD) is the science of predicting fluid flow, heat transfer, mass transfer, chemical reactions and related phenomena by solving the mathematical equations which govern these processes using a numerical process. It is a numerical tool for analyzing two dimensional and three dimensional fluid flow fields in various fields of mechanical engineering streams such as manufacturing area. In the manufacturing area the deep drawing process performance can be improved by using the liquids in the process. The improvement of process performance such as higher in ratio of volume to surface area of product and volume to thickness of product, high quality surface, high accuracy in dimensional , no scratches developed on outer side of cup, higher in limiting drawing ratio and formability index. Deep drawing process is the compression-tension forming process involving wide spectrum of operations and flow conditions. The features of deep drawing process can be developed by fluid pressure for producing the metallic cups. In this process, the pressurized fluid is utilized for many purposes as the sheet metal blank is supported in entire forming process, elimination of fracture in
deformation of cup and formation of wrinkles on the wall and edges of the cup are minimized. In this process the uniform thickness of sheet is obtained even after deformation in plastic region. The fluid pressure is also effects on radial, hoop and drawing stresses of blanks in during the process. The fluid pressures obtained from ANSYS Flotran CFD analysis software for using the fluids such as olive oil, heavy machine oil and castor oils. The Evaluation of fluids pressure by varying the punch radius at constant punch speed.