Doctoral Programme in Mechanical Engineering
Rapid tools in sheet metal forming processes
Doctoral Thesis of Lorenzo Iorio – Supervisor: Prof. Matteo Strano XXX Cycle, Manufacturing and Production Systems
Objectives
Results
References
MeccPhD
Doctoral Programme in Mechanical Engineering
Programme Coordinator prof. Daniele Rocchi
Department of Mechanical Engineering
Via La Masa 1
20156 Milano
info and contact
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Analysis of Traditional stamping tools solutions
Evaluation of materials to be used as an efficient alternative
Investigation of new solution
Application of rapid tools setup in 3 sheet metal forming processes
Experimental analysis Economical comparison Process simulation Development of new solutions: Compensation algorithm (Stamping) Redesigned solutions (Air bending) Prototypal proposal (Rotary draw bending)
FEM models
Strain maps comparison
Fracture analysis
Compensation results
The FEM model is robust in simulating stamping, air bending and rotary drawbending processes
The compensation algorithm is robust also for complex geometries Fatigue tests have been performed, whose results suggest that the tools can be
used in medium production batches The rapid tools developed for air-bending process have similar performances with
respect to commercial solutions (metal and nylon tools) in terms of bend angle andstandard deviation of the process
The rotary draw bending case demonstrates that is not trivial to design a rapid toolssetup, because some involuntary complications can be introduced in the processwith the consequent increase of the tools costs (i.e. pressurized rubber plug)
Analysis of geometrical deviations
Stress Analysis
1. IORIO, Lorenzo; STRANO, Matteo; MONNO,Michele. Development of a Die CompensationAlgorithm for Sheet Metal Stamping WithDeformable Tools. In: ASME 2015 InternationalManufacturing Science and EngineeringConference. American Society of MechanicalEngineers, 2015. p. V001T02A089-V001T02A089.
2. IORIO, Lorenzo; STRANO, Matteo; MONNO,Michele. Rapid Tools Compensation in SheetMetal Stamping Process. In: MATEC Web ofConferences. EDP Sciences, 2016. p. 10009.
3. Iorio, Lorenzo, et al. "Design of DeformableTools for Sheet Metal Forming." Journal ofManufacturing Science and Engineering 138.9(2016): 094701.