Learning experience in designing a dome test setup for sheet metal formability characterization

Abstract

Limiting Dome Height (LDH) test conventionally known as Dome Test is one of the methods that is used in industry for characterization of sheet metal formability. Designing a dome test set up can provide undergraduate students with significant learning experience. The objective of this paper is to discuss the learning experience that has been gained by a team of undergraduate students in designing a dome test setup in a form of a senior design project. A dome test set up is consisted of a punch, die, and blank holder along with instrumentation. Through a contact, the punch forms a flat sheet metal specimen, which is held on its edge by the blank holder, into the cylindrical die cavity in a shape of a dome. The height of the dome is considered as a measure of formability. To achieve a set of pre-defined educational objectives, the design project is defined with specific design requirements and design constraints. Students have worked in a team framework to develop their detailed design approach under supervision of faculty. Students have learned to utilize commercial software ABAQUS for FEM forming simulation of dome test to estimate the maximum punch force needed for successful testing. Students have improved their Computer Aided Design skills in designing the punch, die, and blank holder including the draw beads that can stand the required force estimated by FEM. A force and position sensors are integrated in the design as instrumentation to measure the force and dome height at different stages of deformation. Students have collaborated to build the solid model of the system in SolidWorks. The proper design documentations have been prepared. The learning outcomes and educational benefits of the projects that have been gained throughout the course of two semesters are discussed.