Design and Analysis of Air-Flow Management System in Air Conditioning

Abstract

SPIF (single point incremental forming) is a promising manufacturing technique for small batch manufacturing.Furthermore,duetothesmallplasticzoneandgradualnatureoftheprocess,thematerialformabilityisimprovedas compared to traditional sheet metal forming processes. However, further advancement of the SPIF methodnecessitatesathoroughunderstandingthemechanismofmaterialdeformation,whichiscriticalforprocessoptimization. In this present study a detailed finite element model mimicking the duct of a HVAC system has beendeveloped to analyze the state of strain and stress in the vicinity of the contact region, where plastic deformation iscausedbytheformingtooloperation.ThenumericalmodelisdevelopedinABAQUSforatruncatedpyramidmade of Al6082T6 aluminum alloy, which includes the forming force evolution, final thickness, and plastic straindistributions. The blank is modelled with hexahedral finite elements in order to precisely measure the through-thickness gradients. The limited contact area between the forming tool and the blank results in a negative meanstress at the bottom of the tool, delaying the occurrence of ductile fracture. The residual stresses, on the other hand,are positive in the inner wall of the pyramid and negative on the outer wall in both meridional and circumferentialdirections.Dueto thegeometricalconstraintsin thisdirection,theyoftenoccurin thecircumferentialdirection.