Experimental and Numerical Analyses of the Temperature Field in the Ironing Process

Abstract

The purpose of this paper is to determine the temperature fields in the workpiece and the tool in the ironing process using an integrated approach that includes laboratory experiments and numerical modelling. An originally developed model device for ironing sheet metal strips, which was previously shaped by U-bending, was used for the experimental research. Thermocouples were installed in the device at the position close to the contact surface with the workpiece. The device was mounted on a hydraulic press that enables maximum ironing speeds of v = 4,17 mm/s. In order to determine the temperature fields at higher ironing speeds, a series of numerical experiments was performed at identical speeds as in the experiments (0,33 mm/s and 4,17 mm/s) and at higher speeds (100 mm/s, 1000 mm/s and 10000 mm/s). Good matches of the experimental and numerical results at lower speeds were obtained, so the numerical estimates at higher speeds were valid for the analysis and conclusions. With the increase of the ironing speed, a trend of temperature increase is evident. The maximum temperature of 166 °C at ironing speed of 10000 mm/s that corresponds to manufacturing of 250 cans per minute is significantly lower than the critical melting temperature of the tin coating.

Keywords

• finite element method
• ironing
• numerical simulation
• physical modelling
• temperature