An In-Depth Study on the Impact of Test Parameters on the Erichsen Index and Punch Force

Year 2025, EARLY VIEW, 1 - 1

Fatih Civelek , Ahmet Özdemir

https://doi.org/10.2339/politeknik.1643666

Abstract

In this paper, the Erichsen index (EI) values of the DC04 steel sheets were obtained both experimentally and through finite element analysis. The influences of punch size, punch speed, and thickness level of the sheet on the punch force, EI and fracture strains were examined. The design of the experiments was created using the Taguchi method, and the influences of the factors on the EI value were detected numerically with an analysis of variance (ANOVA). It was observed that the most effective parameter on the EI is the punch diameter. Additionally, it was noticed that the fracture strain and the Erichsen index increased with higher levels of thickness, and the punch speed showed no appreciable impact on the EI value. It was found that as the punch diameter decreased, the impact of sheet thickness on ES and fracture strain increased. The punch force increases almost linearly with both the punch diameter and sheet thickness. The effective strains at the onset of crack formation were calculated mathematically, and simulations were conducted based on these data. The simulation results of the Erichsen tests show strong consistency with the experimental findings, with the Mean Absolute Percentage Error not exceeding 3.5%.

Keywords

Erichsen cupping test, sheet metals, finite element method

Ethical Statement

The authors of this article declare that the materials and methods used in this study do not require ethical committee permission and/or legal-special permission.

Supporting Institution

Gazi University Scientific Research Projects Coordination Unit

Project Number

FDK-2023-8497

Thanks

The authors would like to express their gratitude to the Gazi University Scientific Research Projects Coordination Unit for supporting this study under project number FDK-2023-8497.

Test Parametrelerinin Erichsen Sabiti ve Zımba Kuvvetine Etkisinin Derinlemesine İncelenmesi

Abstract

Bu makalede, DC04 çelik sacların Erichsen Sabiti (ES) değerleri hem deneysel yöntemle hem de sonlu elemanlar analizi ile elde edilmiştir. Zımba çapı, zımba hızı ve sac kalınlığının zımba kuvvetine, ES ve kırılma gerinimi üzerine etkileri incelenmiştir. Deneylerin tasarımı Taguchi yöntemi kullanılarak oluşturulmuş ve faktörlerin ES değeri üzerindeki etkileri varyans analizi (ANOVA) ile sayısal olarak tespit edilmiştir. ES değerini etkileyen en önemli parametrenin zımba çapı olduğu görülmüştür. Ayrıca, kırılma geriniminin ve Erichsen değerlerinin sacın kalınlaşmasıyla arttığı ve zımba hızının ES değerine önemli bir etkisinin olmadığı görülmüştür. Sac kalınlığının ES ve kırılma gerinimi üzerine etkisinin zımba çapının küçülmesiyle arttığı tespit edilmiştir. Zımba kuvvetinin hem zımba çapı hem de sac kalınlığıyla neredeyse lineer olarak arttığı gözlemlenmiştir. Çatlak oluşumu başlangıcındaki efektif gerinimler matematiksel olarak hesaplanmış ve bu veriler yardımıyla simülasyonlar gerçekleştirilmiştir. Erichsen testlerinin simülasyon sonuçları deneysel bulgularla güçlü bir tutarlılık göstermiştir ve Ortalama Mutlak Yüzde Hata %3,5'i geçmemektedir.

Keywords

Erichsen şişirme testi, sac metaller, sonlu elemanlar yöntemi

Project Number

FDK-2023-8497

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