Fatigue of reinforced-polyurethane-based, sheet metal forming dies

Fatigue in metal forming dies is an important issue in the manufacturing industry. Fatigue failure leads to repair or replacement of the die, which interrupts and slows down the manufacturing process. Fatigue of bulk metal forming (such as, forging and extrusion) dies has been the focus of most die...

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Bibliographic Details
Published inInternational journal of fatigue Vol. 28; no. 1; pp. 43 - 52
Main Authors Park, Young-Bin, Colton, Jonathan S.
Format Journal Article
LanguageEnglish
Published Oxford Elsevier Ltd 2006
Elsevier Science
Subjects
Applied sciences
Damage parameter
Exact sciences and technology
Fatigue
Fatigue life prediction
Mechanical properties and methods of testing. Rheology. Fracture mechanics. Tribology
Metals. Metallurgy
Polymer composite
Stress analysis
Stress analysis
Fatigue life prediction
Polymer composite
Damage parameter
Fatigue life
Prediction
Mechanical properties
Fatigue
Forming
Polymer
Composite material
Lifetime
Sheet metal
Polyurethane
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Summary:Fatigue in metal forming dies is an important issue in the manufacturing industry. Fatigue failure leads to repair or replacement of the die, which interrupts and slows down the manufacturing process. Fatigue of bulk metal forming (such as, forging and extrusion) dies has been the focus of most die failure studies because the nature of the process tends to subject the die to high stresses, thus increasing the likelihood of die failure. However, as polymer composite tooling materials are making inroads into rapid tooling technologies, die failure in sheet metal forming, in which the dies are subjected to significantly lower stresses, is drawing attention. This paper presents a fatigue failure analysis of V-bending dies machined from a polyurethane-based tooling board. The mechanical properties of the tooling materials are characterized to identify the underlying failure mechanisms. Various fatigue failure criteria, namely, maximum tensile principal stress, effective stress, Smith–Watson–Topper, and critical plane approaches are investigated as die life prediction methods, among which the latter two approaches were most accurate. Finite element analyses and experiments are performed to verify the results.
Bibliography:ObjectType-Article-2
SourceType-Scholarly Journals-1
ObjectType-Feature-1
content type line 23
ISSN:0142-1123
1879-3452
DOI:10.1016/j.ijfatigue.2005.04.005