Sheet Metal Forming II: Simulation Techniques in Manufacturing Technology

Sheet Metal Forming II
Simulation Techniques in Manufacturing Technology

Lecture 4
Laboratory for Machine Tools and Production Engineering

Chair of Manufacturing Technology
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. F. Klocke
© WZL/Fraunhofer IPT
Outline
1 Introduction
2 Simulation of Sheet Metal forming
3 Case Study
4 Economical aspects of process modelling
© WZL/Fraunhofer IPT Seite 2

Historical development of the FEM
230 v.Chr.: Calculation of the Pi-number and the
circumference by adding of finite number of
filaments (Archimedes of Syrakus)
1851: Solution of the minimal area problem by
Schellbach
Archimedes
1909: Introduction of the Ritz solution method
time
Ritz 1915: Introduction of the weighted residual solution
method by Galerkin
1943: Introduction of the variation solution method
by Courant
Galerkin 1960: The terminology Finite Element Method first
used by Clough
ab 1970: Development of the first commercial FE-
Courant
software
Source: Domenico Fetti, Columbia Encyclopedia

Why process modelling?
Manufacture complex parts Increase quality
Increase reliability Apply new materials

of production Quality (Al, Mg, …)
Reduction of time
Car Body
Use material more
required for training Time Cost efficiently
Reduction of lead Reduction of tool

time Reduction of cost
pre production trials
Source: BMW

Integration of process modelling into the process chain
Process chain
Design Means of production Tool manu-

Part Part
of car facturing
production
design Planning Tool design and testing
exterior
Application
Sheet metal forming simulation

Part evaluation Process optimisation
Software solution
Methods applied: Methods applied:

- 2D modelling - Simulation with membrane elements
- one-step modelling - Simulation with shell elements
- modelling with membrane elements
Short computation time with sufficient High Precision within acceptable
precision computation times
Source: BMW

Outline
1 Introduction
3 Case Study

Commercial FE codes for sheet metal forming
2D Modelling of selected cross sections:

Abaqus www.abaqus.com
Ansys www.ansys.com
Autoform 2D www.autoform.ch
Deform 2D www.deform.com
Marc www.marc.com
Advantages: Disadvantages:
reduced computation time difficult selection of cross sections
to be modelled
less sensitive to quality of input
data less accurate results
usually less input data required
Source: BMW / Fontana Pietro SPA

One-step simulation:
Isopunch
SIMEX
Corps
AutoForm Onestep
...
reduced computation time decreasing significance due to
increasing computing power
usually less input data required
still not very accurate
suitable tool for part evaluation
Source: BMW

Model with membrane elements:

AutoForm Incremental
Abaqus
...
acceptable computation time long computation time
suitable tool for part evaluation problems when severe bending occurs
suitable for process optimisation not accurate enough in predicting wrinkles
basically accurate results requires high quality input data
Source: BMW

Model with shell elements:
PAM-STAMP
Optris
DYNA-Form
Indeed
...
state of the art tools for process long computation time leads to long
optimisation response time
very accurate results requires high quality input data
Source: BMW

Outline
1 Introduction
3 Case Study

Procedure of FE-Analysis
CAD-model
Idealization
Pre-processor Diskretization
Boundary
conditions
 σ 11   G11 G12 0 0 0   ε 11 
σ  G G 22 0 0 0  ε 22 
 22   12  
 τ 12  =  0 0 G33 0 0   γ 12 
    
 τ 23   0 0 0 G 23 0   γ 13 
Solver FE-Analysis  τ 13   0 0 0 0 G13   γ 23 
Interpretation of
Post-processor
the results
Material Laws
Low accuracy / low calculation time Modelling of the material behavior based
on mathematical material laws
Deduction of the modelling parameters
σ σ from experimental data:
– Elastic material behavior: Young’s Modulus,
Poisson’s ratio, elastic anisotropy
ϕ ϕ – Plastic material behavior: flow curve, strain
Elastic Ideal-plastic
hardening parameter, plastic anisotropy
σ σ
Usage of ideal-plastic material models are
mostly sufficient for bulk forming
ϕ ϕ Usage of elastoplastic material models in
Elastoplastic with Plastic with
strain hardening strain hardening sheet metal forming simulations
Consideration of plane anisotropy for sheet
metal forming simulations
High accuracy / high calculation time

Friction laws in metal forming
τR Coulomb friction:
Coulomb friction
τ R = µ ⋅σ N
Shear friction
Shear friction:
kf
Reality
τR = m⋅ k with k=
3
Wanheim and Bay developed a more general
friction law with a continuous transition of the
σN
τR two friction laws mentioned above:
τ R = f ⋅α ⋅ k
Orowan
σN – Normal stress
τR – Shear stress
Reality Shaw /
Wanheim und Bay µ,m – Friction coefficients
f – Friction factor
α – Ratio of the contact areas
σN
Part Evaluation: One step method
Steps:
1) Create mesh from 3D

CAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results
Source: BMW

Steps:

CAD model
4) computation
Source: BMW

Steps:

CAD model
4) computation
Source: BMW

Steps:

CAD model
4) computation
Source: BMW

Steps:

CAD model
4) computation
Source: BMW

Steps:

CAD model
4) computation
Source: BMW

Contact stress distribution for circular tool geometry
Contact-
stresses
σN / MPa A-A
drawing direction
400
70
Punch force FSt / kN

FSt,max = 64,5 kN
300
Contact concentration
200
A-A
0
0 Stroke s / mm 35
100
Anisotropy effect

Alternative tool geometries
Contackt
stresses
σN / MPa
400 Lamé (a = 10 mm; b = 8 mm; n = 4)

Lamé (a = 12 mm; b = 7 mm; n = 3)
FSt,max = 64,5 kN
300 FSt,max = 61,8 kN
FSt,max = 61,8 kN
FSt,max = 60,1 kN
70 FSt,max = 63,1 kN
200
Punch force FSt / kN

Lamé (a = 10 mm; b = 7 mm; n = 3)
100
0 0
Lamé (a = 10 mm; b = 8 mm; n = 3) 0 Stroke s / mm 35

Reduction of stress concentration and wear using the Lamé-curve
Contact stress
σN / MPa
direction of pull direction of pull
Areas with gradually

increased increasing
contact stress contact stress
Circle-curve Lamé-curve

Process optimisation: Forming process
Process
CAD-data Contact Material-
boundary
tool & blank formulation data
conditions
Meshing
GENERIS
PAM-STAMP Input file

Process optimisation: Forming sequence
Source: BMW

Case study: Process optimisation by improved tool design
Part geometry Workpiece end geometry Initial workpiece geometry
Tool geometry (cut view) Tool geometry
Source: BMW

Source: BMW

Source: BMW

Source: BMW

Source: BMW

Source: BMW

Source: BMW

Case study: Evaluation of wrinkling
distribution of effective strain during and after the drawing process

Source: BMW

Process optimisation: Evaluation of wrinkling
distribution of effective stress during and after the drawing process

Source: BMW

Process optimisation: Comparision between simulation and real part
wrinkling
Source: BMW

Process optimisation: Comparision between simulation and real part
rupturing
Source: BMW

Outline
1 Introduction
3 Case Study

Modelling sheet metal forming: Quality of the computed results
Result Quality
qualitatively quantitatively
rupture ++ +
wrinkles ++ ++
springback + 0

Flow chart of a modelling project
Part design Boundary Conditions Simulation
Part Material Tools Process Start tool yes

selection (CAD) Simulation
geometry parameters design
no

Effort for a sheet metal modelling project
Change of responsible effort CAD effort Simulation
Process parameters
Process design ---- 1h --3h
(friction, beads, ...)
die setup (blank holder,

Process design 1d -- 1w 3h -- 1d
etc. ...)
Material quality and

Body design ---- 1h -- 3h
thickness
Part geometry Body design 1d --1w 3h -- 1d
Total effort for a medium sized part: Usually 2 weeks

Preprocessing effort for a modelling project in sheet metal forming
3W
2W
1W
1993 2009
Effort for preprocessing

Development of computing power and computation time
100%
50h
20% 15h
1993 2009 1993 2009

Reduction of computation
Increase of computing power time for a large car body
part

Development of hardware cost
100 %
<1%
1993 2009
Hardware cost

Prerequisites for the industrial application of process modelling
Time: Cost: Quality:
Short response Low project

Reliable results
times cost
Integration into the process chain of a

car body

Simulation of crashworthiness for the Ford Explorer (LS-Dyna)
Source: Livermore Software Technology

Sheet Metal Forming II: Simulation Techniques in Manufacturing Technology

Uploaded by

Copyright:

Available Formats

You might also like

Sheet Metal Forming II: Simulation Techniques in Manufacturing Technology

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sheet Metal Forming II: Simulation Techniques in Manufacturing Technology

Uploaded by

Copyright:

Available Formats

Sheet Metal Forming II

Simulation Techniques in Manufacturing Technology

Laboratory for Machine Tools and Production Engineering

Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. F. Klocke

2 Simulation of Sheet Metal forming

4 Economical aspects of process modelling

© WZL/Fraunhofer IPT Seite 2

© WZL/Fraunhofer IPT Seite 3

Manufacture complex parts Increase quality

Increase reliability Apply new materials

Reduction of lead Reduction of tool

© WZL/Fraunhofer IPT Seite 4

Design Means of production Tool manu-

Sheet metal forming simulation

Methods applied: Methods applied:

© WZL/Fraunhofer IPT Seite 5

2 Simulation of Sheet Metal forming

4 Economical aspects of process modelling

© WZL/Fraunhofer IPT Seite 6

2D Modelling of selected cross sections:

Source: BMW / Fontana Pietro SPA

© WZL/Fraunhofer IPT Seite 7

© WZL/Fraunhofer IPT Seite 8

Model with membrane elements:

© WZL/Fraunhofer IPT Seite 9

Model with shell elements:

© WZL/Fraunhofer IPT Seite 10

2 Simulation of Sheet Metal forming

4 Economical aspects of process modelling

© WZL/Fraunhofer IPT Seite 11

High accuracy / high calculation time

1) Create mesh from 3D

2) create blank holder

© WZL/Fraunhofer IPT Seite 15

1) Create mesh from 3D

2) create blank holder

© WZL/Fraunhofer IPT Seite 16

1) Create mesh from 3D

2) create blank holder

© WZL/Fraunhofer IPT Seite 17

1) Create mesh from 3D

2) create blank holder

© WZL/Fraunhofer IPT Seite 18

1) Create mesh from 3D

2) create blank holder

© WZL/Fraunhofer IPT Seite 19

1) Create mesh from 3D

2) create blank holder

© WZL/Fraunhofer IPT Seite 20

Punch force FSt / kN

© WZL/Fraunhofer IPT Seite 21

400 Lamé (a = 10 mm; b = 8 mm; n = 4)

Punch force FSt / kN

© WZL/Fraunhofer IPT Seite 22

Areas with gradually

© WZL/Fraunhofer IPT Seite 23

PAM-STAMP Input file

© WZL/Fraunhofer IPT Seite 25