Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                
Scribd Logo
Upload

Welcome to Scribd!

  • 104 views

    Sheet Metal Forming Simulation in Industry

    Uploaded by

    sscamd
    Finite element simulation system introduced to industry to be utilized at the stamping tool design section. Present situation of simulation system integrated into CAD is also investigated. The purpose of the paper is to look at present situation offinite element simulation.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd

    Sheet Metal Forming Simulation in Industry

    Uploaded by

    sscamd
    104 views8 pages
    Finite element simulation system introduced to industry to be utilized at the stamping tool design section. Present situation of simulation system integrated into CAD is also investigated. The purpose of the paper is to look at present situation offinite element simulation.

    Copyright

    © Attribution Non-Commercial (BY-NC)

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Finite element simulation system introduced to industry to be utilized at the stamping tool design section. Present situation of simulation system integrated into CAD is also investigated. The purpose of the paper is to look at present situation offinite element simulation.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    104 views8 pages

    Sheet Metal Forming Simulation in Industry

    Uploaded by

    sscamd
    Finite element simulation system introduced to industry to be utilized at the stamping tool design section. Present situation of simulation system integrated into CAD is also investigated. The purpose of the paper is to look at present situation offinite element simulation.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 8
    Materials Processing Technology ELSEVIER Joural of Materials Processing Technology 60 (1996) 19-26 —— Sheet metal forming simulation in industry A. Makinouehi The Institute of Physical and Chemical Research - RIKEN, 2-1 Hirosawa, Wako, 351-01 Japan Abstract In order to see actual present situation of finite element simulation system introduced to industry to be utilized at the stamping tool design section, four different examples are introduced. It is clearly shown from the example that each industry has its own purpose to the simulation; prediction of wrinkle, prediction of surface deflection, study of tearing limit condition, determination of blank geometry, prediction of springback, evaluation of sheet thickness and residual stress, and so on. Present state of simulation systems integrated into CAD is also investigated. Keywords: Finite Element Simulation System, Sheet Metal Forming, Die Face Design 1. Introduction World wide efforts have been made to develop finite element codes to simulate sheet metal forming processes, ‘These codes are expected to be a powerful tools to indus- trial users who are working in the tooling design section. Recent advances of this technological field can be seen ,for example, in the proceedings papers of international con- ferences specified to the sheet forming simulation, such as, Symposium on Computer Modeling of Sheet Metal Form- ing Process (1986) [1], FE Simulation of 3-D Sheet Metal Forming Processes in Automotive Industry (1991) [2] and NUMISHEET98 (1998) [8]. The progress is also clearly seen in the benchmark tests organized under the specific purpose to clarify the prediction capability of sheet form- ing defects; OSU test [4], VDI teat [2] and NUMISHEET93 test [3]. However, in many cases the performance and capabil- ity of individual code demonstrated in a paper and/or a ‘benchmark test are the 60 called "champion data” and thus they are not easily achieved in the industrial production design phase. There always exists a rather large gap be- tween research phase and industrial phase. ‘The purpose of the paper is to look at present situation of finite element simulation system introduced toindustry and to reconsider real requirements from industrial engi- neers, which may give an important information to a re searcher for further development of a finite element eys- tem. 2. Expected role of finite element simulation In order to illustrate the expected role of simulation, let us consider a case of automobile industry. The design and manufacturing procedure of stamping tools used for (0924.0136/96/815 00 © 1996 Elsevier Science SA. All rights reserved PUOM4D136 (96) 02308-5 production of car panels is figured out in Fig. 1, starting from the concept and style design of a new car, and ending with the commencement of production. Absolute time mea- sure is not indicated in the figure, since it depende very much on the policy and technological attitude of individual automobile industry. However, most of industries make very keen efforts to reduce time for manufacturing new stamping tool sets and consequently save cost and re- sourees. Expected role of the finite element simulation is to meet this requirement. Simulation may be effectively performed at five differ- ent stages in Fig. 1 for the purpose of helping decision making in design and modification of parts and tools. The first simulation is at the production process design stage <<1>. Purpose of the simulation at the stage is to make a rough estimation whether panels of new designed car can be formed or not. If answer is “no”, the ear design must be modified. However, at this stage geometry of body parts are not fully described in CAD system and no tool data exists, thus it is not possible to make full simulation. ‘The precise simulation is achieved at stage <3> to de- termine number of stamping steps, such as first drawing, second drawing, trimming, edge bending, and to design die face geometry used at each stamping step. Atthisstage die face geometry is modeled by CAD surface description, and thus modification of die face data is made rather eas- ily according to the simulation results on same CAD sys- tem. The performance of integrated CAD and simulation system is crucial for obtaining well optimized stamping steps and die face shape in very limited time allocated to the production tool design. ‘The simulation isalso required at the tryout stage <4>, to find a solution to avoid the forming defects appeared during tryout. In order to study the mechanism of origination and A. Makinowchi / Journal of Materials Processing Technology 60 (1996) 19-26 a Suing stung ot suaringot cr me Sei Suen mom Sates —— > >i a | Rois a) Pein ro prem doe cecen pes te] S fool desig ton lit ant cit ferme anata ery ree TE 1 a =e role ving] et | [pose Ta ‘Simulation gy Ges Fig. 1 Design and manufacturing process of stamping tools in automobile industry. - PRESENT propagation of defects, the systematic series of simula- tion can be taken place after production stated <6 >, and obtained information is efficiently made use of in the next new model. ‘Ascume that the finite element simulation is powerful enough to predict all the forming defects and provide opti- mum stamping tools and conditions, we may completely eliminate the prototype tools from the design and manu- facturing procedure, and we also reduce number of trial and modification operations. Thus the process might be shorten dramatically as is illustrated in Fig. 2. This is the most ideal attitude of the finite clement simulation sys- tem in sheet metal forming industry. 3, Existing simulation code A powerful finite element code is primary important to construct a simulation system. Finite element codes parr ticipated to the benchmark test of NUMISHEET93 [3] are listed in Table 1. Three different benchmark problems are proposed by the organizer; square cup deep drawing (in- tending to prediction of wrinkling and splitting for rather simple geometry), front fender stamping (prediction of wrinkling and splitting for very complex tool geometry), and 2-D draw bending (prediction of springback). The prob lems participated by each code are marked in the table. Finite element codes developed specifically for sheet metal forming simulation may be classified by its formu- lation and time integration algorithm as classified in Table 1. There are many investigations for comparison between classified methods, and advantage and drawback of each method are pointed out [6-71. If we make a very rough con- ceptual evaluation of each method, following remarks may be stated. Rigid plastic or rigid-viscoplastic finite element method. Formulation and implementation is rather simple, and fast calculation is achieved. Due to lack of the elastic re- gion in material model, itis not possible to calculate ini- Simulation <>

    You might also like