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Verification of Numerical Simulation Using a 3D Optical System for Measuring Deformations
Zakl, Alexandr ; Peterková, Eva (referee) ; Řiháček, Jan (advisor)
This master’s thesis discusses the current state of optical metrology and its place in manufacturing and optimization of parts made by deep-drawing technologies. First part is devoted to building a solid knowledge base in different fields that this thesis draws from. These fields are Optical Metrology, deep drawing of sheet metal and simulations using finite elements method. Subsequently, in the experimental part there are chapters dedicated to Measurement and creation of material models and measurement of grid markings on deep-drawn parts provided by ACO Industries, measured by photogrammetric system from German Company GOM metrology. Additionally, for reference to the measurement, FEM software called PAM-Stamp is used to simulate and predict the final state of the parts after manufacturing. Furthermore, optical metrology was used during creation of material models, data supplied by this analysis was used as an input for the simulations. The last chapter then deals with the evaluation and comparison of measured and simulated data and drawing conclusions about the reliability of optical systems and modern technologies in technical practice.
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Manufacturing of the electric motor cover
Kolář, Zdeněk ; Svoboda, Petr (referee) ; Císařová, Michaela (advisor)
The bachelor 's thesis focuses on the design of the production of an electric motoro cover made prom low-carbon steel 11 305 with a thicnkess of 1,5 mm. For an annual production series of 100 000 pieces per year, the technology of deep drawing without wall thinning has been selected. In the practical part, it was found that the cover body can be produced in a single drawing operation. The blank diameter, increased by the trimming allowance, is 212 mm, which will be produced by cutting from coils with a width of 222 mm and a outer diameter of 1200 mm. Total fore of 249,18 kN includes the drawing component, holder and ejector. Production is carried out on the CUPJ 63 DEU hydraulic press from HŠV Polička, equipped with a lower hydraulic device. Deep drawing die is designed for the machine, which enables the production of the cover body in one drawing operation. Design is supplemented with a detailed assembly procedure. Lubricant MORLAUB KFP 61 V is used for optimal process condition.
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Design for Manufacturing of a Cover
Rusková, Marie ; Císařová, Michaela (referee) ; Řiháček, Jan (advisor)
The thesis deals with the design of the air conditioning cover, which will be placed on the roof of the bus. The part is made of 17 240 stainless steel, which is suitable for cold forming, due to its outdoor environment. Deep drawing is chosen as optimal after assessing possible production technologies. Furthermore, the most suitable shape of the blank is proposed and the necessary calculations are carried out, which are verified by numerical simulation. The deep drawing will take place in one operation. Hydraulic press CTH 250 is chosen based on the required force 554.5 kN
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The production of a gully
Králíček, Václav ; Jopek, Miroslav (referee) ; Peterková, Eva (advisor)
Aim of the thesis is possible innovation in production of a body of floor gully. Material of the gully is an austenitic stainless steel 1.4301 (X5CrNi18-10). This particular gully belongs to floor drainage portfolio of ACO Industries k.s., which is a world leading company in drainage systems. The current welded variant has been replaced by a combination of conventional drawing and dimpling. The geometry of the drain bottom was designed in accordance with the requirements of the ČSN EN ISO 14159 standard and EHEDG documents on the hygiene of equipment for use in the food industry. Technological calculations were made for the new designed geometry, the bottom of the inlet will be made in one drawing operation together with the dimpling of the pre-made hole. The production process was verified using numerical simulation. Part of the solution was the production of a prototype for testing of the flow rate. During the flow rate test, the requirements given by the standard were fulfilled. Combined tool for drawing and dimpling was designed. The tool is designed for use in hydraulic press Dieffenbacher PO250 II with magnetic tool clamping. The financial savings compared to the current floor drain design are about 243,43 CZK. With a specified production series of 700 pieces per year with an expected increase of 15 % in the following years, the return on investment for the purchase of the tool was calculated to be 2,65 years.
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Design for Manufacturing of Wheel Hub Cover
Kunc, Ondřej ; Jopek, Miroslav (referee) ; Řiháček, Jan (advisor)
The thesis deals with the design of the production of a wheel hub cover made of 17 350 stainless steel. The cover is in the form of a cylindrical cup with a diameter of 74.5 mm with a flange and a depression in the bottom. The wall thickness is a constant 1 mm. For the production of the series of 100 000 pieces was chosen conventional deep drawing technology. The choice of the technology is followed by technological calculations. The part will be produced in three drawing operations followed by a calibration operation. Verification of the manufacturability of the proposed process was carried out by numerical simulation in PAM - STAMP software. All operations including blank cutting and flange cutting will be performed in one tool clamped in a Dieffenbacher PO 250 hydraulic press.
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Production of components deep forming
Stloukal, Mojmír ; Benč, Marek (referee) ; Císařová, Michaela (advisor)
The aim of this thesis is to create a research study addressing the issues of deep drawing parts with wide flanges. This work includes the process and technological calculations for drawing rotational parts without flanges and the differences in the technological process for producing parts with wide flanges. Furthermore, the utilization of parts with wide flanges in practical applications is summarized.
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Manufacturing of the wheel center cap
Jiřánek, Jakub ; Štroner, Marek (referee) ; Císařová, Michaela (advisor)
The bachelor´s thesis deals with the production of a protective rotary wheel center cap for the hub shaft of a car. It is made of steel 11 320 and the production volume has been set at 120 000 units per year. Among the possible manufacturing technologies, deep drawing was chosen as the most suitable. The diameter of the blank from which the cover is drawn was determined by calculation to be 110 mm. The number of drawing operations was calculated to be one. The total force required for the manufacture of the component was calculated to be 85 kN. According to decisive criteria, a single-acting hydraulic press CUPS 16 DEU from HŠV Polička was chosen, for which a drawing tool was designed. Finally, drawing documentation was created for the cover, assembly of the tool with the die, punch, blank holder and the body of the blank holder.
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Manufacturing of kitchen sink
Vágner, Lukáš ; Peterková, Eva (referee) ; Jopek, Miroslav (advisor)
The project deals with the design of production of the kitchen sink made of chromium-nickel austenitic steel 1.4301. Material thickness of the sink is 1 mm. The annual production series is 30,000 pieces. After considering the size of the produced series, a combination of shearing and deep drawing was chosen as the production technology. Shearing of the circular shape was combined with the execution of both draws into one production tool. For this design, the necessary calculations were performed along with verification by simulations in the PAM-STAMP program.The tool is clamped in a hydraulic press PO 400, which has all the necessary parameters. The coil blank is guided through the unwinding and straightening device Compact Line GLK3-1000. The selling price of one sink was set at CZK 1,300. Production becomes profitable after producing 7540 sinks.
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Production of filter cover
Bachurek, David ; Forejt, Milan (referee) ; Podaný, Kamil (advisor)
The project elaborated design of technology production of the filter cover - section from the deep drawing sheet 11 325 (DC04). Based on analysis was chosen combination of technologies shearing and deep drawing for that option was designed manufacturing process. Forming process is realized on hydraulic progressive press from Sweden company AP&T which has got total nominal tensile force 1740 kN and equipped 5 stations with lower holders and upper ejectors. Deep drawn part is transported between stations by feeders which are part of press. Function parts are made from alloyed tool steels 19 436 and 19 573 which are heat-worked according to drawing documentation. In chapter technical and economical evaluation was determined turning point which become after reaching of 142 840 parts.
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Design production of sink
Pecha, Oldřich ; Dvořák, Milan (referee) ; Podaný, Kamil (advisor)
Thesis submits concept of the sink fabrication technology where circular sink is made from rustproof austenitic steel 1.4301 (X5CrNi 18-10) using technology of conventional deep drawing without reducing wall’s thickness. Hydraulic press YL32 - 400 with nominal force 400 kN has been chosen as the production machine. Drawing tool with holder was designed to be used for this technology and its drawing documentation had been enclosed in this thesis. Size of the production series was set for 20 000 products annually. Control simulation of the drawing process has proven that designed component can be made and that computations are correct. Economic and technological estimation was performed which resulted in price being set for 555 czech crowns per piece. After manufacturing first 7 447 products the manufacturing process will become economically profitable.
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