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Experimental investigation of sheet metal forming using a recyclable low melting point alloy tool

Untersuchung der Metallblechumformung unter Verwendung eines recyclingfähigen Werkzeuges aus einer niedrigschmelzenden Legierung
  • Ismail Durgun , Abdil Kus , Ali Sakin , Ertu Unver , Brian Jagger , Emre Doruk and Fehim Fındık
From the journal Materials Testing

Abstract

Due to intense competition in automotive industry, new car models have to be launched as quickly as possible. A re-evaluation of the design and development phases has reshaped product development in order to get product earlier than competitors. Prototype production is one of the longest stages of product development due to physical verification activities. Shortening of this process will provide more opportunity to get project schedule earlier. Rapid prototype technologies are usually used as a guide for visual and packaging analysis. However, there is a requirement to use these parts for functional testing as well. Developing alternative rapid tooling methods which shorten the physical prototype production phase, while adequately supporting visual, packaging and functional aspects of sheet metal forming, can lead to considerable savings in vehicle prototype development. In this study, sheet metal prototype part using recyclable low melting point alloy was experimentally investigated by analysing dimensional conformance of tools and parts. In addition to wear performance, thickness reduction was investigated for stamped parts.

Kurzfassung

Aufgrund des intensiven Wettbewerbs in der Automobilindustrie müssen neue Fahrzeugmodelle so schnell wie möglich auf den Markt gebracht werden können. Um ein Produkt früher als die Wettbewerber fertig zu haben, wurde die Produktentwicklung durch eine Re-Evaluierung des Designs und der Entwicklungsphasen verändert. Die Prototypherstellung ist aufgrund der physikalischen Nachweisuntersuchungen eine der längsten Phasen in der Produktentwicklung. Eine Verkürzung dieses Prozesses gibt mehr Möglichkeiten den Projektplan zu verkürzen. Techniken des Rapid Prototypings werden üblicherweise als Richtlinie für die visuelle und die Verpackungsanalyse verwendet. Doch es besteht auch die Anforderung, diese Teile ebenfalls für die funktionale Prüfung zu verwenden. Die Entwicklung von alternativen Werkzeugen für das Rapid Prototyping, die die physikalische Prototypherstellungsphase verkürzen und die gleichzeitig adäquat die visuellen, Verpackungs- und funktionalen Aspekte der Metallblechumformung unterstützen, können zu bemerkenswerten Kosteneinsparungen in der Fahrzeugprototypentwicklung führen. In der diesem Beitrag zugrunde liegenden Studie wurde ein Prototypteil aus Metallblech unter Verwendung einer recyclingfähigen, niedrigschmelzenden Legierung experimentell untersucht, in dem die dreidimensionale Übereinstimmung der Werkzeuge und Teile analysiert wurde. Zusätzlich zum Verschleißverhalten wurde die Reduzierung der Dicke der Stanzteile untersucht.


*Correspondence Address, Dr. İsmail Durgun, Tofas R&D, Yeni Yalova Yolu Caddesi No. 574, 16369 Osmangazi, Bursa, Turkey, E-mail:

Dr. Ismail Durgun received his BSc degree in Mechanical Engineering from Uludağ University in Bursa, Turkey in 1988. He worked as a research assistant at that university from 1989 to 1993. He received his MSc degree in Mechanical Engineering from Istanbul Technical University, Turkey, in 1991, and his PhD degree in Mechanical Engineering from Uludağ University in 1999. He has been working for Tofas in Bursa, Turkey, since 1993, and he is the Administrator of Advance Research Department in R&D. His main research areas are rapid prototyping, low volume sheet metal, plastic and composite part production, manufacturing technologies as well as automotive design and production. He is the author of about 75 publications.

Dr. Abdil Kus received his BSc and MSc for studies on the topic of “Hot Forging Die Design” from Gazi University, Institute of Science and Technology, Ankara, Turkey, in 1984 and 1989, respectively. In 1996, he received his PhD for studies on the topic of “Ballistic Impact of Aramid Fabric Composite Panels” from Institute of Science and Technology, University of Uludağ, Bursa, Turkey. He has been working at Uludağ University since 1990, and he is currently working as Associate Professor and Head of the Mechanical Engineering Department. His main research areas are computer aided design and manufacturing technologies, polymer based composites and machinability of materials.

Ali Sakin received his BSc degree in Mechanical Engineering from Uludağ University, Bursa, Turkey, in 2001. He started his professional carrier as project responsible and CAD/CAE consultant at an engineering company in 2001. He received his MSc degree in Mechanical Engineering from the Institute of Natural & Applied Sciences of Uludağ University. Then, he started his PhD education in Mechanical Engineering at Uludağ University in 2011. He is currently taking part in prototype manufacturing studies for testing and development.

Dr. Ertu Unver is a principle enterprise fellow (Reader) at the University of Huddersfield, UK, School of Art, Design and Architecture since 2014. He was anindustrial design engineer in various British companies from 1994 to 1999. He has 10 years of industrial and 25 years of academic experience in teaching, research on digital technologies, product design, engineering and software development. He is currently the course leader for MA 3D digital design course and CAD/CAM manufacturing and technology specialist for product design courses.

Brian Jagger studied at the University of Huddersfield, UK, before working in industry between 1976 and 1982, when he took up a career in further and higher education. From 1996 until 2010, he had a lecturing and management role in product and transport design at the University of Huddersfield as Senior Lecturer and also as Programme Manager with responsibilities for a number of further education courses in the School of Art Design and Performing Arts at Huddersfield Technical College. His research interests are in product innovation and sustainable product development.

Emre Doruk is a researcher at Tofas R&D Center, Bursa, Turkey. He received his BSc degree in Mechanical Engineering from Uludağ University, Bursa, Turkey, in 2010. He worked as a research assistant for Bursa Technical University, Turkey, from 2011 to 2014. His main scientific interests include light weighting, AHSS, aluminum alloy, rapid prototyping, sheet metal forming and crashworthiness.

Dr. Fehim Fındık is Professor in the Department of Metallurgy and Materials Engineering, Technology Faculty, Sakarya University, Turkey. He received his PhD in Materials Engineering from the University of London, London, UK, in 1992. His main scientific interests include materials science and engineering, especially composite processing, advanced alloys, powder metallurgy applications, advanced welding applications, phase transformations, wear, heat treatment and mechanical behavior of materials.


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Published Online: 2016-04-22
Published in Print: 2016-05-02

© 2016, Carl Hanser Verlag, München

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