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Part Manufacturing by Using Hydroforming and Its Optimization
Chrz, Jan ; Jopek, Miroslav (referee) ; Řiháček, Jan (advisor)
The thesis presents an analysis and optimization of the manufacturing process of a part using the technology of parallel hydroforming. Two circular blanks made of DC01 steel with a thickness of 1 mm serve as a semi-manufactured part. In one of the blanks, the supply of the forming medium is constructed using Flowdrill technology. Subsequently, the two blanks are laser welded together and then formed. Numerical simulation using PAM-STAMP software was used to analyse the manufacturing process. This analysis provided information on wall thinning, deformation size, critical points on the product and springback. The numerical simulation was verified on the basis of comparison with an experiment. The criterion for verification was the course of the thickness of the part. Based on the results of the simulation, an optimization is performed in the thesis. It consists in determining the minimum required pressure of the forming medium for pressing the part, particularly for different distances between the two formed sheets.
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Influence of anchor stamping process on the function of pressure control valve
Koumar, František ; Jopek, Miroslav (referee) ; Peterková, Eva (advisor)
The project elaborated a possible simplification of the tool which is used for stamping of the anchor of pressure control valve (PCV). PCV is manufactured at Bosch Diesel s.r.o. Jihlava. The resulting change will reduce the cost of tool production. Current tool can be manufactured only in one company in order to achieve precise dimensions. Based on the comparison of internal stamping, it obtains the dispersion of depths for further tests. Optimal a force is obtained from these tests, followed by limit sample tests. The tests show that modified tool is not suitable for stamping on the force for anchors with limited hardness. It is necessary to use a more suitable variant. A more suitable variant is stamping on the track. With this method, there will be less effect of the hardness of the anchor. The test on stamping on the track will be performed in the second half of 2020 and, if successfully validated, will be introduced into the series.
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Design of wheel hub production
Šidlák, Filip ; Jopek, Miroslav (referee) ; Podaný, Kamil (advisor)
The thesis deals with the design the technology production of wheel hub for the automotive industry made of C45 steel. After the evaluation of suitable technologies, a die forging on a mechanical press was selected. On the basis of technology analysis, the component shape was modified, all allowances and dimensional tolerances were set. According to calculated forming force, the crank press LZK 3150B with nominal force 31, 5 MN from the manufacturer Šmeral Brno, a. s., was chosen. Manufacturing is divided into two operations, pre-forging and after that final forging. Design of dies is based on the ČSN 22 8306 standard and they are made of tool steel of grade 19 552 with the subsequent heat treatment. The dies have upper and lower ejector for easier removal of the forged piece.
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Bulk forming technology of piston of disk brake
Kiza, Jakub ; Jopek, Miroslav (referee) ; Forejt, Milan (advisor)
The master’s thesis presents a proposal for the manufacturing technology of a disk brake piston made of material ČSN 41 2010 for a car brake caliper. Method of cold volume forming was chosen due to the production requirement of 200 000 parts per year, convenient axisymmetric shape of the part and required size tolerance. Based on study of chosen technology, production technique, which contains calibration and backward extrusion, was designed. Technological computations and optimalization of tool dimensions were done for the chosen production technique. The manufacturability of the part was verified by numerical simulation in Simufact Forming software. Because of unavailability of automatic cold forming machine designed for bigger sized parts on the market, the forming process is done by two forming tools with use of INWORK 700 hydraulic press. For the selected profit of 20 % the price for the part was set at 26,8 Kč. The turning point was determined as 52 745 pieces.
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Manufacturing of the part "shaker" by cold sheet metal forming
Pekař, Pavel ; Císařová, Michaela (referee) ; Jopek, Miroslav (advisor)
The project elaborated design of technology production of the extract from the stainless deep drawing sheet 0,3 mm steel 17 240. Pursuant to of the literary pursuit a problem of the sheering and deep drawing was designed sheering and drawing with blank holder in combined tool. The tool is solved like customary rack with guiding rods clamped on the hydraulic press for forming of sheet PO 100 with nominal forming force 1 000 kN. Shearing die, drawing die and drawing punch are produced from tool steel 19 436.9 heat-worked according to drawing documentation.
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Suitable lubricants for deep drawing of carbon steel plate
Poloch, Milan ; Císařová, Michaela (referee) ; Jopek, Miroslav (advisor)
The task of the diploma thesis is to design and manufacture a testing jig, which will then be used for experimental testing of lubricants for drawing stampings up to 4 mm thick. The drawn material is deep-drawn steel D04. Friction modeling between the traction edge and the retainer was used for a real simulation of the production process. The shaped traction edge was constructed on the basis of a real part. A total of 6 types of lubricants were tested, of which one lubricant in the form of a paste was selected as the reference. The other lubricants were then compared with the reference value of the measured maximum tensile force. The aim was to ensure a lubricant in a consistency other than paste. Of the oil lubricants we received, none of the lubricants approached the optimum values.
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Production of a hollow pin by cold forming
Šanca, Kristián ; Řiháček, Jan (referee) ; Jopek, Miroslav (advisor)
The hollow pin with a length of 45 mm and a diameter of 28 mm made of 12 050 steel is produced by cold cold forming. It showed defect-translation and the goal was to eliminate it by optimization. 10 variants were proposed, of which No. 10 was without defects and the goal of the work was met. The forming process was simulated by Simufact Forming software. The semi-finished product is a block made of a round bar 18 x 35.68. The part is manufactured on a process tool for 4 operations by a combination of upsetting and extrusion. The machine used is the CBF-204L automatic machine. The required force is 3 042 kN. The price of 1 piece is CZK 19.59. 120,000 pieces are produced annually.
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Piston rod eye production
Hořava, David ; Jopek, Miroslav (referee) ; Lidmila, Zdeněk (advisor)
The bachelor's project elaborated design of technology production of the piston rod eye in series of 45 000 pieces. The piston rod eye is made of steel rod C45E by die forging. Pursuant to of the literary pursuit and necessary technological calculations was chosen a pneumatic – hydraulic hammer KHZ 4A, from the company called Šmeral, with a forming energy of 50 kJ, for forging of component. Cross wedge rolling machine was chosen for overdosage of forged piece in form of double piece. Shearing press LKOA 200, from the company called Šmeral, with a forming force of 2 000 kN, was chosen for shearing of forged piece. At the end, the technical – economic evaluation of material costs was calculated.
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Heat treatment of formed parts
Leška, Radim ; Jopek, Miroslav (referee) ; Lidmila, Zdeněk (advisor)
In the research part, the bachelor thesis deals with forming, the mechanism of plastic deformation and steels used for forming. It also describes the principles of heat treatment, specifically the methods used in the preparation of semi-finished products, pressings, and forgings, i.e., annealing, hardening, and tempering. In the practical part, several experiments were performed on C45 steel. The first of them verified the effect of strain hardening after compaction, the others were focused on recrystallization, full annealing, hardening, and tempering. The effect of deformation and heat treatment was assessed in terms of hardness, which was measured by the Vickers hardness test.
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Development of an impactor for the Taylor anvil test
Müller, Samuel ; Forejt, Milan (referee) ; Jopek, Miroslav (advisor)
The Master Thesis describes the differences between quasi-static and dynamic material tests and discusses the effect of strain rate in forming processes. It contains a detailed description of Split Hopkinson pressure bar test, Split Hopkinson tensile bar test and Taylor anvil test. The thesis contains a basic theory of ballistics and the history of the development of the material sample carrier for the Taylor test and the analysis of its current state. A new sample carrier was developed for the adjusted diameter of the Taylor test equipment. The shape of the carrier was designed, based on simulations in ANSYS software and practical testing. The carrier was made by 3D printing technology, FDM method. Samples of aluminum alloy 2024-T3 were tested using the new samples carriers. Dynamic flow stress was determined, and the strain rate constant was optimized for specifics impact velocities.
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