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A study of vibro-acoustic behaviour variation of thin sheet metal components manufactured through deep drawing process

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Deep drawing is one of the most widely used manufacturing methods in the automobile industry. Therefore, a thorough understanding of this method is very important. Only for certain kinds of materials the forming process knowledge to achieve the desired dimensional accuracy is currently available. With the advent of different kinds of steels—corrosion resistant, dent resistant and cost-effective alloys—in the market, the deep drawing manufacturing method gained a significant momentum in the recent past. Achieving the desired dimensional accuracy of a designed part still remains a challenge as complex phenomena including spring-back are associated with the manufacturing process. It is often seen that the deep drawing process results in both geometric profile and thickness variations as compared to the nominal part design. These deviations are important with respect to the geometrical dimensional accuracy, but in addition they can also have a significant effect on the vibro-acoustic behaviour of the manufactured components. Hence, most often the simulation results of a nominal CAD part design using Finite Element Analysis (FEA) do not represent the actual behaviour of the component. In this research paper, a variation analysis—using both simulation and experimental methods—of a component manufactured through deep drawing, starting from a blank sheet made of mild steel material, is presented in a systematic manner. After a thorough analysis of the dynamic behaviour of the blank, an industrial component—an oil pan look-a-like—with a high draw ratio is designed, manufactured and analysed for understanding the impact of geometrical deviations on it’s vibro-acoustic behaviour. The geometry of the actual component is obtained through a white-light scanning process. It is observed that a geometry profile deviation up to 5 mm and a thickness variation of 40% occurred in the actual manufactured part as compared to the nominally designed part. The eigenfrequencies of the actual part have deviations up to 14% as compared to that of the nominal part. The mode shape comparison—using the Modal Assurance Criterion (MAC)—between the experimental and the simulation results proves the necessity of incorporating geometric deviations. The acoustic simulation results obtained from the geometries of the nominal CAD design and the actual part are compared and it is found that the actual part design results are in good agreement with the experimental results. Hence, this paper focuses on establishing the importance of considering geometry and thickness deviations, that occur in the deep drawing process, when predicting vibro-acoustic properties. It is demonstrated that there is a significant increase in the accuracy of the simulation predictions by incorporating the manufacturing effects.
Tijdschrift: Applied Acoustics
ISSN: 0003-682X
Issue: 2018
Volume: 153
Pagina's: 110 - 126
Jaar van publicatie:2019
BOF-keylabel:ja
IOF-keylabel:ja
BOF-publication weight:1
CSS-citation score:1
Auteurs:International
Authors from:Government, Higher Education
Toegankelijkheid:Closed