03_SpringbackCompensationSeminar_StepbyStep
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Transcript of 03_SpringbackCompensationSeminar_StepbyStep
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Springback Springback CompensationCompensation SeminarSeminar
StepStep byby StepStep
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
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Current Challenges
Physical tool geometry correction loops are timePhysical tool geometry correction loops are time-- and and costcost--intensiveintensiveSimulationSimulation--based springback compensation eliminates based springback compensation eliminates compensation loopscompensation loops
Accurate simulation Accurate simulation of springback of springback
Effective compensationEffective compensationof active surfaces of active surfaces
StartStart
Physical tryoutPhysical tryout
Simulation Simulation based tryoutbased tryout
Part geometryPart geometrySpringback resultSpringback result
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
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Springback Compensation - Workflow
ToleranceToleranceokayokay??
CompensationCompensationstrategystrategy
* * SurfaceSurface constraintsconstraints* * CompensationCompensation factorfactor
CompensationCompensationactiveactive surfacessurfacesAF-Compensator
Process optimal?
Spring-back
robust?
Simulation ofSimulation ofRobustnessRobustness
AF-Sigma
Simulation ofSimulation ofSpringbackSpringback
AF-Incremental
Simulation Simulation ofofthethe processprocess
AF-IncrementalAF-DieDesigner
AF-Trim
Export ofExport ofcompensatedcompensated
active surfacesactive surfacesor vector field or vector field
Process & Geometry optimizationProcess & Geometry optimizationAF-Incremental, AF-DieDesigner
Springback Springback evaluationevaluation
Confirmation Confirmation Simulation Simulation
AF-Incremental
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Springback Compensation The Principles
Principle 1: You require a proper basic simulationPrinciple 1: You require a proper basic simulationPrinciple 2: In order to execute a springback simulationPrinciple 2: In order to execute a springback simulation
Final Validation Settings are requiredFinal Validation Settings are requiredPrinciple 3: Evaluate springback in a well defined andPrinciple 3: Evaluate springback in a well defined and
repeatable wayrepeatable wayPrinciple 4: Ensure the process is stablePrinciple 4: Ensure the process is stablePrinciple 5: Compensation just does; it doesntPrinciple 5: Compensation just does; it doesnt
interpret or evaluateinterpret or evaluate
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Springback Compensation Step by Step
Step 1: Proper Basic SimulationStep 1: Proper Basic SimulationStep 2: Simulation of SpringbackStep 2: Simulation of SpringbackStep 3: Springback EvaluationStep 3: Springback EvaluationStep 4: ProcessStep 4: Process-- and Geometryand Geometry--improvement improvement Step 5: Process RobustnessStep 5: Process RobustnessStep 6: Compensation StrategyStep 6: Compensation StrategyStep 7: Compensation active SurfacesStep 7: Compensation active SurfacesStep 8: Export Compensation ResultsStep 8: Export Compensation ResultsStep 9: Confirmation SimulationStep 9: Confirmation Simulation
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Example
Springback Compensation Springback Compensation Step by Step will Step by Step will be be illustrated on one example: Sillustrated on one example: S--RailRailWe will make use of both:We will make use of both:
Slide PresentationSlide PresentationAutoForm Software DemonstrationAutoForm Software Demonstration
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Step 1: Proper Basic Simulation
Step 1 identical to Principle 1Step 1 identical to Principle 1
Part must met the final quality demands before an accurate Part must met the final quality demands before an accurate springback simulation will be executedspringback simulation will be executed
Free of splitsFree of splitsFree of wrinklesFree of wrinklesFinal blank shapeFinal blank shape
Development of an optimal forming process using AutoFormDevelopment of an optimal forming process using AutoFormProcess layout, concept, draw die geometryProcess layout, concept, draw die geometryConsideration of all OPConsideration of all OPs, optimal Process parameters, optimal Process parameterClamping conditions of measuring deviceClamping conditions of measuring device
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Preprocessing
Simulation setSimulation set--up of inner partsup of inner partsGeometry / Tools definitionsGeometry / Tools definitionsBlankBlank
Material dataMaterial dataBlank shapeBlank shape
Process definitionProcess definitionTool penetration Tool penetration kinematic checkkinematic checkDraw beadsDraw beadsSecondary operationsSecondary operations
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Evaluation of Inner PartsEvaluation of Inner PartsGeneral Overview: General Overview: Formability Formability Analyze the Analyze the SplitsSplitsAnalyze the Distribution of Sheet ThicknessAnalyze the Distribution of Sheet ThicknessAnalyze the Analyze the Occurrence of WrinklesOccurrence of WrinklesAnalyze the Punch ImpactAnalyze the Punch ImpactAnalyze the Binder ClosureAnalyze the Binder ClosureAnalyze the Analyze the DrawDraw--InInCheck Check BlankholderBlankholder Pressure DistributionPressure Distribution
PostprocessingVersion 1.1
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Forming of S-RailVersion 1.1
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Part from AutoFormPart from AutoFormMaterial and thicknessMaterial and thickness
SPCC (2.00 mm)SPCC (2.00 mm)Binder TravelBinder Travel
100 mm100 mmBinder ForceBinder Force
600 KN (600 KN (apprappr. 60 ton). 60 ton)
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Forming of S-RailVersion 1.1
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Second Operation: Second Operation: CuttingCutting
FinallyFinally, Springback, Springback
First Operation: DrawingFirst Operation: Drawing
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Software demo Step 1Version 1.1
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Simulation setSimulation set--up Sup S--RailRail
ResultResult evaluation of Sevaluation of S--RailRail
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Step 2: Springback Simulation
Final Validation SettingsFinal Validation SettingsConvergence behaviorConvergence behaviorFree springback vs. Constrained springbackFree springback vs. Constrained springback
Local best fitLocal best fitPositioning of clamps and pilotsPositioning of clamps and pilots
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
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Step 2: Springback simulation
Checklist: Checklist: Final ValidationFinal ValidationChecklist: Checklist: Final ValidationFinal Validation-- ElasticElastic PlasticPlastic ShellShell-- StandardStandard--settingssettings plus:plus:-- Initial Initial elementelement sizesize: :
2 2 * min. * min. DieDie--radiusradius (max(max. 20 . 20 mm)mm)-- Max Max refinementrefinement levellevel:: 5 5 -- Max Max elementelement angle: angle: 22.522.5-- EndTimeStepEndTimeStep: 0.4 : 0.4 --
AutoForm developed Final Validation Settings for a fast and AutoForm developed Final Validation Settings for a fast and accurate springback resultaccurate springback result
Starting point of Step 2 is Principle 2Starting point of Step 2 is Principle 2
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Springback (x mm)Springback (x mm)Springback (x mm)
Compensation Strategy Influence of clamping conceptVersion 1.1
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Springback (x mm) Springback(x mm)
StartingStarting Point Point Free SpringbackFree Springback
Constrained springback is always recommended in the Constrained springback is always recommended in the springback compensationspringback compensationTry to minimize the clamping pointsTry to minimize the clamping pointsTry to define the clamping concept with minimum Try to define the clamping concept with minimum springback deviation which aims at minimizing the surface springback deviation which aims at minimizing the surface change during the compensationchange during the compensationClamping concept influences the springback resultsClamping concept influences the springback results
ConstrainedConstrainedSpringbackSpringback
ConstrainedConstrainedSpringbackSpringback
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Positioning of Clamps
In reality,In reality, the the Sheet has a certain Sheet has a certain thicknessthicknessClamp position is well definedClamp position is well defined
In the simulation, only the In the simulation, only the mid plane of the sheet is mid plane of the sheet is representedrepresentedThe clamp position must The clamp position must be defined carefully:be defined carefully:TopTop -- Mid Mid -- BottomBottom
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Step 3: Springback Evaluation
Clamping Concept & Clamping ForcesClamping Concept & Clamping ForcesReference GeometryReference GeometrySpringback resultsSpringback results-- distance from referencedistance from reference
Springback result variables are always measured from part to Springback result variables are always measured from part to reference geometryreference geometry
Reference GeometryReference Geometry
Part after SpringbackPart after Springback
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Software Demo Step 2 & 3
Step 2: Springback SimulationStep 2: Springback SimulationStep 3: Springback EvaluationStep 3: Springback Evaluation
Evaluation of clamping forcesEvaluation of clamping forcesEvaluation of springback values Evaluation of springback values
The shape deviation varies from -3.5mm to 0.4mm, which exceeded the given tolerance, therefore, springback compensation is necessary.
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Step 4: Process- & Geometry- improvement
Modification of:Modification of:Process settingsProcess settingsTool GeometryTool GeometryPart GeometryPart Geometry
in order to reduce or even eliminate springbackin order to reduce or even eliminate springback
In case of the SIn case of the S--Rail, Rail, blankholderblankholder force just before bottom force just before bottom stroke has been increasedstroke has been increased
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Part 1: accurate springback simulationPart 1: accurate springback simulationStep 1: Proper Basic SimulationStep 1: Proper Basic SimulationStep 2: Springback SimulationStep 2: Springback SimulationStep 3: Springback EvaluationStep 3: Springback EvaluationStep 4: ProcessStep 4: Process-- and Geometryand Geometry--Improvement Improvement
Part 2: effective springback compensationPart 2: effective springback compensationStep 5: Process RobustnessStep 5: Process RobustnessStep 6: Compensation StrategyStep 6: Compensation StrategyStep 7: Compensation active SurfacesStep 7: Compensation active SurfacesStep 8: Export Compensation ResultsStep 8: Export Compensation ResultsStep 9: Confirmation SimulationStep 9: Confirmation Simulation
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Version 1.1
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Step 5. Process Robustness
InputInput
O
u
t
p
u
t
O
u
t
p
u
t
RobustnessRobustnessThe characteristic of the process to be insensitive The characteristic of the process to be insensitive to the variation of the inputto the variation of the input
Initial SimulationInitial Simulation
Improved simulationImproved simulation
Material variation at Material variation at improved simulationimproved simulationNew SimulationNew SimulationMaterial variation at Material variation at new Simulationnew Simulation
RobustnessRobustnessAnalysisAnalysis
Process Process improvementimprovement
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
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Robustness Analysis - how does it work?
Noisevariables
Definition of Process Environment Multiple Simulations
Evaluation, Statistic process control
Influence and sensitivity
Process potential
Dominant variable
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
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Industrial Application of Robustness Analysis
Front Front sideside membermember innerinner Volvo C30/S40/V50 Volvo C30/S40/V50 ((**))
((**
) ) Influence on simulation results from material and process scatter, Sigvant & Carleer, IDDRG, Porto 2006Influence on simulation results from material and process scatter, Sigvant & Carleer, IDDRG, Porto 2006
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Version 1.1
Industrial Application of Robustness Analysis
FailureFailure
Simulation showed a feasible Simulation showed a feasible partpart
1.01.00.80.80.60.6
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
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Industrial Application of Robustness Analysis
but despite of a safe simulation occurrence of but despite of a safe simulation occurrence of problems problems in productionin production
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
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Industrial Application of Robustness Analysis
InputInput OutputOutput
Specificationlimit
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
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Industrial Application of Robustness AnalysisModification of radius in critical zone resulted Modification of radius in critical zone resulted in a more stable production processin a more stable production process
OutputOutput
Specificationlimit
OutputOutput
Specificationlimit
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
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Industrial Application - Summary
InputInput
O
u
t
p
u
t
O
u
t
p
u
t
OutputOutput OutputOutput
Process improvement II &Process improvement II &Robustness analysis IIRobustness analysis IIpart is feasible and part is feasible and production is reliableproduction is reliable
Robustness analysis IRobustness analysis Ipart production is not part production is not reliable reliable
Process improvement IProcess improvement Ipart is feasible part is feasible
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Step 5. Process RobustnessVersion 1.1
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InputInput OutputOutput
It is strongly recommended to assure that your process is stable by It is strongly recommended to assure that your process is stable by using AutoFormusing AutoForm--Sigma. Compensations is only reasonable with a Sigma. Compensations is only reasonable with a robust springbackrobust springback
FormingFormingprocessprocess
4.31.0 8.7
(Springback,(Springback,mm)mm)
How much must the tool be compensated?How much must the tool be compensated?Compensation doesnt guarantee success Compensation doesnt guarantee success
AutoForm developed an inputAutoForm developed an input--set for AutoFormset for AutoForm--Sigma in order to Sigma in order to properly represent the real life result variationproperly represent the real life result variation
Step 5 is identical to Principle 4: ensureStep 5 is identical to Principle 4: ensure the process is stablethe process is stable
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Robustness Analysis - InputVersion 1.1
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Parameters & Ranges forParameters & Ranges for robustness analysisrobustness analysisThickness, Thickness, Norm Norm 10% 10% Mechanical Properties, Rp0.2 Mechanical Properties, Rp0.2 20MPa, 20MPa, RmRm 20MPa (dependent )20MPa (dependent )RR--Values, Values, 20% (dependent ) 20% (dependent ) Blank holder pressure, Blank holder pressure, 10%10%Lube, Lube, 10%10%Blank position, Blank position, 1mm1mm
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Software Demo Step 5: Process Robustness
Process Robustness with respect to:Process Robustness with respect to:FeasibilityFeasibilitySpringbackSpringback
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Step 6. Compensation strategy
Carefully consider how to compensate the forming Carefully consider how to compensate the forming processprocess
Which operation etc.Which operation etc.Surface constraintsSurface constraintsCompensation factor (Default = Recommendation = 1)Compensation factor (Default = Recommendation = 1)
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
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Compensation Strategy A: Structural Parts
OP20:OP20:GravityGravityClosingClosingDrawingDrawing
OP40:OP40:CuttingCutting
OP50:OP50:CuttingCutting
OP60:OP60:CuttingCuttingSpringbackSpringback
OP30:OP30:CuttingCutting
Vector Vector field of OP60 is processed on part geometry field of OP60 is processed on part geometry ((--> > all operations are compensated same as OP20)all operations are compensated same as OP20)After After OP60 springback of part should be within required tolerances OP60 springback of part should be within required tolerances otherwise additional otherwise additional compensation loops are compensation loops are requiredrequiredBecause of different springback at the end of each operation, Because of different springback at the end of each operation, problems while loading following die might occurproblems while loading following die might occur
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
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Compensation Strategy B: Structural Parts
Each Each forming operation forming operation is compensated individually is compensated individually After After OP50 springback of part should be within required OP50 springback of part should be within required tolerances tolerances otherwise additional compensation loops are requiredotherwise additional compensation loops are requiredBecause of different compensation geometries of each operation, Because of different compensation geometries of each operation, positioning in next tool must be done carefullypositioning in next tool must be done carefully
OP20:OP20:GravityGravityClosingClosingDrawingDrawingSpringbackSpringback
OP30:OP30:CuttingCutting
OP40OP40::PositioningPositioningClosingClosingFormingFormingSpringbackSpringback
OP50OP50::PositioningPositioningClosingClosingFormingFormingSpringbackSpringback
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Compensation StrategyVersion 1.1
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Springback (x mm)
Free springback)Free springback)
OP20:OP20:GravityGravityClosingClosingDrawingDrawing
OP30:OP30:CuttingCutting
OP40OP40::FormingForming
OP50OP50::FormingFormingSpringbackSpringback
Springback (x mm)
ConstrainedConstrained springbackspringback
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
1ste Iteration (x mm)
1ste Iteration (x mm)
1ste Iteration (x mm)
1ste Iteration (x mm)
First First compensationcompensation looploop
Strategy A -Version 1.1
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StartingStarting pointpoint
Springback(x mm)
Springback (y mm)
2te Iteration (y mm)
2te Iteration (y mm)
2te Iteration (y mm)
2te Iteration (y mm)
Second Second compensationcompensation looploop
Springback OK
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Step 7: Compensation of Active Surfaces
Application of AutoFormApplication of AutoForm--CompensatorCompensator
Keep in mind Principle 5: Keep in mind Principle 5: Compensation just does; it doesnt interpret or evaluateCompensation just does; it doesnt interpret or evaluate
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Version 1.0
Springback Compensation
ExampleExample: : CompensationCompensation ofof a Cross a Cross membermember
The The formingforming, , cuttingcutting andand springback springback hashas to to bebe calculatedcalculated asas basisbasis forfor thethecompensationcompensation..
As As thethe entireentire tooltool geometrygeometry isis to to bebe compensatedcompensated in in thethe DrawDraw stagestage, , ModMod 22 hashas to to bebe selectedselected..
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Version 1.0
Springback Compensation
ExampleExample: : CompensationCompensation atat a Cross a Cross membermember
UsingUsing thethe PredefinePredefine compensationcompensation regionsregions, , thethe areasareas forfor thethecompensationcompensation areare determineddetermined automaticallyautomatically..
BinderBinder: The : The defineddefined binderbinder isis fixedfixed ((FixedFixed).).PartPart: The original : The original partpart datadata areare compensatedcompensated accordingaccording to to thethe springback springback resultsresultsbyby thethe factorfactor 11. . FillFill andand AddendumAddendum definedefine thethe transitiontransition areaarea..
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Version 1.0
Springback Compensation
Example: Compensation at a Cross memberExample: Compensation at a Cross memberAfter After ApplyApply the tool surfaces are modified.the tool surfaces are modified.
In the section, the sprung back part, the reference geometry and the In the section, the sprung back part, the reference geometry and the compensated punch are shown. compensated punch are shown. The part is sprung back upwards with respect to the reference The part is sprung back upwards with respect to the reference geometry. geometry. Thus, the geometry is corrected in the opposite direction, Thus, the geometry is corrected in the opposite direction, accordingly. The punch (as all the other tools in the Process accordingly. The punch (as all the other tools in the Process generator) is automatically adopted and is positioned below the generator) is automatically adopted and is positioned below the reference geometry.reference geometry.
StempelStempelReferenzgeometrieReferenzgeometrie
aufgefedertes Bauteilaufgefedertes Bauteil
Reference GeometryReference GeometryNew PunchNew Punch
Sprung back PartSprung back Part
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Springback CompensationVersion 1.1
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Compensation area of the SCompensation area of the S--RailRailDirect compensation is only possible in those area where springback Direct compensation is only possible in those area where springback results are available.results are available.
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Principle 5: Compensation just doesVersion 1.1
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First compensation loopFirst compensation loopStraight forward compensation gives swinging of the Straight forward compensation gives swinging of the blankholderblankholderManual manipulation necessaryManual manipulation necessary
Think of principle 5: compensationThink of principle 5: compensation just doesjust doesThe compensation just takes the available springback result to The compensation just takes the available springback result to extract the toolextract the tool geometry, no further interpretation or evaluation has geometry, no further interpretation or evaluation has been done been done
For beam-like part or the case of part on binder, the quality of binder surface after compensation is the typical issue.
Improve the distorted binder surface
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Smooth Binder SurfaceVersion 1.1
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Desired shape
Improved binder surface
Manual manipulationManual manipulation executed with morphing functionality of executed with morphing functionality of AutoFormAutoForm--DieDesignerDieDesignerBlankholderBlankholder looks smooth nowlooks smooth now
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
The max. shape deviation still exceeded the given The max. shape deviation still exceeded the given tolerance after one compensation loop.tolerance after one compensation loop.Introduce 2Introduce 2ndnd and 3and 3rdrd compensation until given tolerance is compensation until given tolerance is reachedreached
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Convergence of Compensation LoopsThe convergence behavior can be both oscillating or The convergence behavior can be both oscillating or asymptotic (impossible to say in advance what it will be)asymptotic (impossible to say in advance what it will be)
0 1 2 3 4 5# iteration loop
D
i
s
t
a
n
c
e
f
r
o
m
r
e
f
e
r
e
n
c
e
0
oscillating oscillating convergenceconvergenceasymptotic asymptotic convergenceconvergence
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Software demo Step 6 & 7
Step 6: Compensation StrategyStep 6: Compensation StrategyStep 7: Compensation Active SurfacesStep 7: Compensation Active Surfaces
The final shape deviation after 4 compensation loops The final shape deviation after 4 compensation loops The shape deviation is wellThe shape deviation is well--controlled under 0.25mmcontrolled under 0.25mm
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Software demo Step 6 & 7
The final shape deviation after 4The final shape deviation after 4thth Compensation loops Compensation loops The shape deviation is wellThe shape deviation is well--controlled under 0.25mmcontrolled under 0.25mm
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Starting point 1st Iteration
4th Iteration
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Step 8: Export Compensation Results
How to get the data out of AF into a CAD system?How to get the data out of AF into a CAD system?Export compensated meshExport compensated meshImport in CADImport in CADReRe--design in CAD based on imported AFdesign in CAD based on imported AF--compensatedcompensated meshmeshIn special cases, use vector field to deform existing CADIn special cases, use vector field to deform existing CAD--surfacessurfaces
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Step 9: Confirmation Simulation
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Execute anExecute an AutoForm simulation based on the AutoForm simulation based on the compensated tool surface as final check before millingcompensated tool surface as final check before milling
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Version 1.1Version 1.1
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Springback Compensation - Workflow
ToleranceToleranceokayokay??
CompensationCompensationstrategystrategy
* * SurfaceSurface constraintsconstraints* * CompensationCompensation factorfactor
CompensationCompensationactiveactive surfacessurfacesAF-Compensator
Process optimal?
Spring-back
robust?
Simulation ofSimulation ofRobustnessRobustness
AF-Sigma
Simulation ofSimulation ofSpringbackSpringback
AF-Incremental
Simulation Simulation ofofthethe processprocess
AF-IncrementalAF-DieDesigner
AF-Trim
Export ofExport ofcompensatedcompensated
active surfacesactive surfacesor vector field or vector field
Process & Geometry optimizationProcess & Geometry optimizationAF-Incremental, AF-DieDesigner
Springback Springback evaluationevaluation
Confirmation Confirmation Simulation Simulation
AF-Incremental
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Influence on your Working-Process
ToolProduction Tryout
Tool Design
ProcessPlanningFeasibility
Future Procedure:Future Procedure:The process engineer develops a compensationThe process engineer develops a compensationstrategy at an early stagestrategy at an early stageThe necessary springback and compensation The necessary springback and compensation knowknow--how has been developedhow has been developedThe active surfaces are already compensated The active surfaces are already compensated in the engineering department. in the engineering department.
Tryout samples have been measuredTryout samples have been measuredA compensation strategy is determinedA compensation strategy is determinedGenerally the process engineer is not involvedGenerally the process engineer is not involved
Present Procedure:Present Procedure:
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Tips for Successful Implementation
Before Springback compensationBefore Springback compensationThe base simulation should have no splits, no wrinkles and no The base simulation should have no splits, no wrinkles and no issues of blank size change;issues of blank size change;Springback should be minimized through process improvement.Springback should be minimized through process improvement.
Springback compensationSpringback compensationThe distortion of binder surface after compensation is the typical The distortion of binder surface after compensation is the typical issue of compensation for beamissue of compensation for beam--like part, or the case of part on like part, or the case of part on binder;binder;To improve the binder surface, additional morph has to be To improve the binder surface, additional morph has to be introduced.introduced.Attention: Only the fix region and transition region can be Attention: Only the fix region and transition region can be modified after compensation. The region of direct compensation modified after compensation. The region of direct compensation is not allowed to be changed after compensation. is not allowed to be changed after compensation.
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
Tips for Successful Implementation
After Springback compensation, After Springback compensation, Inform the tryInform the try--out worker that this is a compensated tool so the out worker that this is a compensated tool so the process must be adjusted to the simulation as much as possibleprocess must be adjusted to the simulation as much as possibleBe present at the tryBe present at the try--out to learn and to discus any additional out to learn and to discus any additional change of tool surfaceschange of tool surfaces
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Summary and Perspective
Springback simulations can reliably be performed with Springback simulations can reliably be performed with AutoForm Final Validation settingsAutoForm Final Validation settingsSpringback compensation can productively be applied using Springback compensation can productively be applied using AutoFormAutoFormCompensation strategies can be complexCompensation strategies can be complexSpringback simulation and springback compensation require Springback simulation and springback compensation require additional expertise of the useradditional expertise of the user
AutoForm offers you support AutoForm offers you support for the implementation of for the implementation of this leading edge technology this leading edge technology
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Springback Springback CompensationCompensation Seminar, ChennaiSeminar, Chennai, July 9, 2010, July 9, 2010
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Thank YouThank You