Automotive manufacturers are continuously striving to meet economic demands by designing and manufacturing more efficient and better performing vehicles. To aid this effort, many manufacturers are using different design strategies such to reduce the overall size/weight of certain automotive components without compromising strength or durability. Stainless steel is a popular material for such uses (i.e. bumpers and fuel tanks) since it possesses both high strength and ductility, and it is relatively light for its strength. However, with current forming processes (e.g., hot working, incremental forming, and superplastic forming), extremely complex components cannot always be easily produced, thus, limiting the potential weight-saving and performance benefits that could be achieved otherwise. Electrically-Assisted Manufacturing (EAM) is an emerging manufacturing technique that has been proven capable of significantly increasing the formability of many automotive alloys, hence the “electroplastic effect”. In this technique, electricity can be applied in many ways (e.g., pulsed, cycled, or continuous) to metals undergoing different types of deformation (e.g., compression, tension, bending). When applied, the electricity lowers the required deformation forces, increases part displacement or elongation, and can reduce or eliminate springback in formed parts. Within this study, the effects of EAM on the bending of 304 Stainless Steel sheet metal will be characterized and modeled for different die widths and electrical flux densities. In previous works, EAM has proven to be highly successful on this particular material. Comparison of 3-point bending force profiles for non-electrical baseline tests and various EAM tests will help to illustrate electricity’s effectiveness. An electroplastic bending coefficient will be introduced and used for modeling an electrically-assisted bending process. Additionally, the springback reductions attained from EAM will be quantified and compared. From this work, a better overall understanding of the effects and benefits of EAM on bending processes will be explained.
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ASME 2010 International Manufacturing Science and Engineering Conference
October 12–15, 2010
Erie, Pennsylvania, USA
Conference Sponsors:
- Manufacturing Engineering Division
ISBN:
978-0-7918-4946-0
PROCEEDINGS PAPER
Modeling and Quantification of the Electroplastic Effect When Bending Stainless Steel Sheet Metal
Wesley A. Salandro,
Wesley A. Salandro
Clemson University, Greenville, SC
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Cristina Bunget,
Cristina Bunget
Clemson University, Greenville, SC
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Laine Mears
Laine Mears
Clemson University, Greenville, SC
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Wesley A. Salandro
Clemson University, Greenville, SC
Cristina Bunget
Clemson University, Greenville, SC
Laine Mears
Clemson University, Greenville, SC
Paper No:
MSEC2010-34043, pp. 581-590; 10 pages
Published Online:
April 11, 2011
Citation
Salandro, WA, Bunget, C, & Mears, L. "Modeling and Quantification of the Electroplastic Effect When Bending Stainless Steel Sheet Metal." Proceedings of the ASME 2010 International Manufacturing Science and Engineering Conference. ASME 2010 International Manufacturing Science and Engineering Conference, Volume 1. Erie, Pennsylvania, USA. October 12–15, 2010. pp. 581-590. ASME. https://doi.org/10.1115/MSEC2010-34043
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