Prediction Of Flange Wrinkles In Intelligent Deep Drawing For A Rectangular Box

In many cases the presence of wrinkles is unacceptable for the final product and the purpose of assembly. Because of many different effects in deep drawing for a rectangular box, the process become very complex and there is no perfect wrinkling criterion for a rectangular box forming. Therefore, the research of wrinkling is both of great significance for the development of stamping theory and the practice of curved parts production. The law of flange wrinkling for rectangular box deformation has been studied in this paper, and form the energy method, the analytical rule for the wrinkling is derived when material property parameters, dimensions of the sheet and die are considered. Using finite element method (FEM) simulation, the blank holder force(BHF)for flange wrinkling is gained on the base of analysis of wrinkling height in different BHF and drawing depth. And the results are in excellent agreement with theoretical results. Real-time monitoring and control depend on the development of data acquisition (DAQ) technology. Based on the portable DAQ system of LabVIEW, the signal acquisition and sensor calibration both get the satisfied speed and precision of signals. The merits such as the high speed of dater acquisition, the strong anti-interference ability of signal and high precision for this new DAQ system can cover the shortage of former DAQ system based on control software Genie . The mobile digitizing system ATOS (Advanced Topometric Sensor) has been used to test the accuracy of flange wrinkling. Compare with conventional measure method, this system has the features such as reliability and simple operation, flexibility and mobility, high detail resolution and accuracy which increase the precision of the experimental system of intelligent deep drawing for the wrinkling prediction. On the base of the criterion for the wrinkling and FEM simulation under the real condition, the experiment research for wall wrinkling of rectangular box deep drawing is carried and the results which provides the data indicates the theory analysis is reliable and effective are gained. The experiment research proves the theory analysis for the wrinkling in deep drawing can also be used to design the tooling, process parameters and the basis of intellectual control in sheet metal forming.