Finite element analysis, experimental investigation and process parameter optimization of sheet metal bending by line heating method.

Abstract

The present study concerned with finite element analysis and experimental investigation of sheet metal deforming by line heating method that incorporates the combined effect of traverse speed of the torch, thickness of the sheet metal and number of passes of the torch. For the numerical analysis of metal bending by line heating, the finite element method is employed and the design of an experiment with an orthogonal array L9 is used for the experimental investigation and parameter optimization. Mild steel of 300 x 200 mm is used for both the numerical and experimental investigation. The results from the two approach shows that thermal deformation of the sheet metal mainly depends on geometrical parameters like the thickness of the metal. From the result, a 2 mm thickness metal with a 5mm/s travel speed and single-pass line heating is the best optimum combinations for the maximum temperatures and deformations. The deformations generated from this case are 0.25 mm from the reference plane with a peak temperature gradient of 667.5℃. And also, for the required amount of deformation, the thickness has a significant effect than travel speed and number of passes with a percentage contribution of 93.48%, 5.69%, and 0.41% respectively. And also, for the two approaches, numerical modeling is well agreed with the experiments. Finally, it has been shown that the numerical modeling of the moving heat source developed for this purpose accurately predicts the real process in a mechanical workbench with a user interface.