3DSfinal
Transcript of 3DSfinal
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3DS
Digital Die Design System
Final Report
March 2003
Contributors: The 3DS Consortium
Editor: Naomichi Mori / CIMTOPS CORPORATION
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1. Summary of Project
1.1 Introduction
The 3DS project was carried out as part of the Intelligent Manufacturing Systems (IMS) program,
with research partners from Japan, the EU, Canada and Swiss.
The ultimate aim of the project is to develop a digital die design system (3DS) for sheet metal
forming processes. 3DS should be a software system capable to aid sheet metal stamping die
design, by carrying out the computer tryout, instead of the actual tryout. This will save time,
money and resources.
A number of CAD systems for designing sheet metal forming tools have been developed, mainly in
the automotive industry, some of them being incorporated with finite element software. They are
intended to predict the eventual occurrence of forming defects and to optimize the shape of
stamping tools in the design stage. However, the performance of such systems is still far below the
original expectations, in spite of the progress achieved in both the physical and numerical
modelling of the process. The main reasons of this partial failure are:
- use of non-standardized and generally poor methods of quantitative evaluation of forming
defects,
- lack of rigorously-controlled experimental data on the forming processes producing defects,
- lack of an unbiased evaluation of the ability of the available physical models and numerical
software to predict forming defects.
The present project was carried out with three objectives that are aimed at significantly improving
this state of the art and which are considered as crucial for constructing an intelligent die design
system.
The first objective of the project is to develop definitions and methods of quantitative evaluation of
geometrical forming defects. A user-friendly, graphical software library is developed to illustrate
and quantitatively evaluate the forming defects on the computer. This processor system will
significantly facilitate the comparison of CAD, experimental and simulation data, thus providing a
key tool for the computer tryout of stamping tools.
The second and main objective is to conceive and perform a comprehensive set of benchmark
tests which enables to evaluate the ability of numerical codes to predict forming defects. In such
benchmark tests, obtaining reliable reference experimental data plays a key role. It is, therefore,
intended to promote a strong cooperation between the consortium partners performing the same
tests, in order to adopt and promote uniform experimental conditions and similar procedures of
defect measurement and evaluation. Furthermore, different types of finite element codes is used
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for simulating the benchmark tests, in order to appraise the capability of various mechanical
models and numerical algorithms to predict forming defects.
The third objective of the project is to develop guidelines for selecting the most appropriateelastoplastic constitutive models for predicting various forming defects, as well as realistic friction
models to be used in computer simulations. The selected elastoplastic laws is identified and
validated by using sequences of tensile and simple shear experiments on sheets of several steels
and aluminium alloys. The friction laws is determined by using experiments as closed as possible
to the real contact conditions occurring during sheet metal forming. A special attention was given
to the optimum implementation of the selected models in the finite element codes used for the
benchmark simulations.
The results of the present project are expected to form the basis for achieving the final aim of
constructing an intelligent die design system for sheet metal forming.
1.2 PROJECT OBJECTIVES
A number of CAD systems for designing sheet metal forming tools have been developed, mainly in
the automotive industry. Some of them are incorporated with finite element software. They are
intended to carry out "tryout" on the computer, predicting the occurrence of forming defects and
optimizing the shape of stamping tools in the design stage (see Figure.1). However, the
performance of these systems has been rather far below the original expectations.
Indeed, the forming defects, such as wrinkles or surface deflection (see Figure 2) are at present
evaluated merely by visual inspection of experienced engineers or by mechanical procedures,
such as digital touch and stoning (hand - flat grinding to reveal surface unevenness). Detailed
measurements on 3D benches are scarce, due to the price and duration of such measurements.
A rather subjective evaluation method is also most often applied to defects predicted by
simulation. Moreover, the very definition and characterization of forming defects seems to vary
from one plant to another, and this renders very difficult the comparison of the results. To
significantly improve this situation, it is essential to establish a widely accepted system of
definitions and measurement procedures of forming defects.
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Figure 1. Present state of die design manufacturing process
As for the present ability of numerical methods to simulate sheet forming processes, it is beyond
any doubt that no single software can predict all types of forming defects. There are many finite
element codes employing different methods for sheet forming simulation, such as the rigid-plastic
or the elastoplastic methods, employing explicit or implicit time-integration schemes, the one-step
inverse method, and so on. At several international conferences, for example the VDI International
Conference held at Zurich, Switzerland in 1991, NUMISHEET'93 held at Isehara, Japan in 1993,
and NUMISHEET'96 held at Dearborn, USA in 1996, benchmark tests were organized to appraise
the capability of such methods to predict forming defects. However, most of the benchmark
experimental results obtained by different participants disagreed greatly with each other and thus
provided very poor reference data to evaluate the software. These unsatisfactory results are
largely due to the diversity of the tools employed (state of wear, surface quality, lubrication) and to
the insufficient control of the processing parameters, e. g. the blank holding force, which plays a
very significant role in the amount of the resulting springback (see Figure 3). Moreover, most of the
benchmark problems focused on the prediction of strain distribution, which can express only one
type of forming defect. For these reasons, the evaluation of the ability of numerical methods and
software to simulate forming defects is still incomplete and hardly reliable.
Numerical results are also strongly affected by physical models such as the material and friction
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models. It is therefore essential to improve these physical models in order to obtain satisfactory
accuracy, especially for forming processes involving double-sided control of the sheet, large
plastic deformations and/or strain-path changes.
Figure 2. Defects of sheet metal forming
BHL=190KN
BHL=95KN
BHL=25KN
Figure 3. Springback of a U-profile after deep-drawing of a steel sheet with
different blank holding loads (BHL)
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1.3 Project Structure
The project partners have backgrounds in the product and process engineering and/or in thecomputer and engineering sciences. All partners have specific know-how in the area of sheet
metal forming processes. The inter-regional consortium consists of 14 industrial companies, 1
national research institutes or organizations and 5 universities, from 9 countries belonging to four
IMS regions. The technical background of the partners is indicated in Table 1. This rather strong
participation is required in view of the large amount of experimental work (benchmark tests,
identification of material and friction laws) and of the numerical simulations which are necessary
for achieving a high reliability of data.
Table.1 Technical Background of the Consortium Members
Region Consortium Member Technical Background
Canada Forming Technologies
Incorporated
Developing non-linear FE codes
ARCELOR (France) Producing metal sheets
EU Cockerill-Sambre R&D (Belgium) Producing metal sheets
DaimlerChrysler AG (Germany) Producing automobiles
ESI (France) Developing software for sheet metal forming
Pechiney CRV (France) Producing metal sheets
Renault (France) Producing automobiles.
Volvo Car Corporation (Sweden) Producing automobiles
UTS S.p.A. (Italy) Product and process engineering, mainly for
automotive industry
CNRS-LPMTM (France) Developing material models and implementing
them into FE codes
FEUP-DEMEGI (Portugal) Developing experimental devices for tests on
metal sheets
DEM-FCTUC (Portugal) Developing FE codes
FAMOTIK, Ltd. Producing CAD software
Japan NISSAN MOTOR Co., Ltd. Producing automobiles.
PRESS KOGYO Co., Ltd. Producing member parts for trucks and buses.
TSUBAMEX Co., Ltd. Producing tools for sheet metal forming and
related software
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Osaka Institute of Technology,
Dept. of Mechanical Engng.
Producing FE codes
University of Tokyo, Institute ofIndustrial Science
Developing new technologies in the field ofsheet metal forming
GSIS of Tohoku University Developing advanced techniques for material
characterization
Switzerland AutoForm Engineering GmbH Developing software for sheet metal forming
2. Research of Work Package
2.1 Work Package Plan and Summary of Results
In the 3DS project, the following three work packages are proposed and carried out.
WP1: Development of user-friendly methods and software for evaluating forming defects.
WP2:Evaluation and improvement of the ability of numerical software to predict forming defects.
WP3: Selection of appropriate physical models and their identification.
All three work packages are very closely related with each other as shown in Fig 4.
Fig.4 Relation among Work Packages in the 3DS.
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Workpackage 1: Development of user-friendly methods and software for evaluating
forming defects
Scope and objectives
The existence of forming defects is currently checked by means of visual, tactile or mechanical
inspection, a process which can hardly be systematized, due to the difficulty of comparing actual
products and designed products on a quantitative basis.
Another problem concerns the use of numerical results obtained in forming process simulation to
evaluate formability and to make comparisons with designed products. For example, when
evaluating the amount of "springback" of a part that has a complicated three-dimensional shape, it
is very difficult to make a meaningful comparison between a resulting numerical shape and the
original designed shape without a sound methodology.
It is thus clear that the prediction and the quantitative evaluation of forming defects requires a
unified treatment of three different types of geometrical data:
CAD data as reference models, which are represented as surface models.
CAE data resulting from computer simulations, which are represented as nodal
co-ordinates of the mesh.
Measurement data from real physical objects, which are represented as co-ordinates of
some selected points.
The goal of WP1 is to establish a methodology for characterizing and evaluating the forming
defects. The methodology should be incorporated into a user-friendly, digital environment, a
numerical tool which could be possibly utilized even without possessing outstanding skills of sheet
metal forming processing.
To attain this goal, conventional evaluation methods need to be restructured into a new formalism
which should possess three essential properties: computer readable and repeatable
representation, simple implementation, and clear validation.
Description of the work
Task 1: Standardization of object data and necessary conditions for data acquisitionConventionally, the shapes of real formed products have been examined by visual inspection and
measurement, by using such tools as jigs, gauges, calipers, and so on. To make a quantitative
evaluation of forming defects and a meaningful comparison, it is essential that unified treatment of
three different types of geometry. In this task, we aimed at determining common formats for
geometrical data such as CAD data, CAE results, and measurements data and to develop the
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matching method for co-ordinate systems of different types of data within this task. However, for
the common format mentioned above, the data acquisition method should be made under
standard conditions. These should consist of measurement procedures and of a method forpost-processing the measurement data.
Summary of Results:
The matching method for co-ordinate systems targeted specific shapes were developed. In the
Phase 2, further development will be made so that some other shapes can be treated.
Task 2: Definition of forming defects
It is essential to share clear and compatible definitions of forming defects between different
companies and institutes belonging to the consortium. A classification of forming defects and
definition of intrinsic values for surface and geometrical defects were developed. Self-sufficient
definitions of these features without redundancy was given by using certain extensions of the
differential geometry of surfaces. The surface of each defect model has some global features,
which describe overall distortions, such as the surface being "bent" or "twisted", and local features,
which describe local distortions and their locations.
Summary of Results:
Various type of forming defects appearing during press forming sheet were classified and defined
by European Partner and Japanese partner. It was separated into two categories, one directly
interesting in the project. Because a name and definition of defects vary according to countries, it
had modified and added and finally agreed about the contents.
Task 3: Characterization and evaluation of forming defects
Establishment of a reliable method for characterization and evaluation of forming defects is one of
the most important tasks of work package 1. A robust method for the extraction of intrinsic values
defined in task 2 from discrete point data such as measurement data or simulation results was
developed. A verification method, as well as algorithms for derivation of defect models from
examples of the format defined in task 1, were also proposed and tested. Task 3 includes also the
developing of a new filtering method for noisy measurement data.
Summary of Results:
One of important task, the evaluation methods were developed that allow us to grasp a cause of
defects quantitatively on the computer. In the Phase I, we developed Springback(2D) evaluation
method, Surface Strain evaluation method. With these evaluation methods, quantitative
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evaluation became possible. In the Phase 2, we extended targets, a method for 3 dimensional
shape and twisting are carried out.
Task 4: Development of a defect evaluation processor
Software modules are needed to systematize the evaluation method of forming defects, because
they should replace complicated operations that are usually performed by experienced engineers.
The modules are consist of functions for calculating the characterization parameters and to
recognize the forming defects according to the definitions proposed in task 2.
Task 4 provides the basic modules for constructing a forming defect evaluation processor. This
software library also includes the graphic modules which can display the location of the forming
defects, thus allowing to estimate and control the product quality in the forming process.
Summary of Results:
The software incorporated evaluation methods developed in Task 3 were developed. Tried to
apply to actual forming process, we could confirm the effectiveness that this software was
applicable to actual forming products. However, applicable shape is limited to specific shape
targeted in the project. In the Phase 2, we are tackling with new target shape for practical
application.
Workpackage 2: Evaluation and improvement of the ability of numerical software to predict
forming defects
Scope and objectives
WP2 aims at evaluating and improving the ability of numerical codes to predict such forming
defects. An essential task of this workpackage is to establish, perform and thoroughly document a
set of reliable experimental benchmark tests for evaluating the ability of a numerical code to
predict forming defects.
We also investigate the characteristics of the numerical methods and codes developed and/or
used by the consortium partners, by using the results of the benchmark tests, in order to develop
the most appropriate numerical methods for evaluating forming defects during the product and tool
design stage.
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Description of the work
Task 1: Definition of a set of experimental benchmark tests for evaluating numericalmethods
In press stamping, a variety of parts, such as a very large and complex-shaped automobile body
panel, a thick and large truck frame member, or a medium-sized deeply drawn cup, are formed by
using tools that have different sizes, shapes and structures. On the other hand, in the press
stamping process, many different forming defects are observed, such as tearing, wrinkling,
surface deflection, springback, twisting, and surface damage. It is well known that no single
numerical software can simulate all stamping processes and/or predict all types of forming
defects. Therefore, appropriate standard benchmark tests are needed, in order to evaluate the
applicability of numerical software to a specific process for predicting defects with sufficient
accuracy. The aim of this task is to perfectly define the conditions of such tests.
To this end eight representative benchmark tests have been selected in order to study a large
variety of forming defects (see Fig. 5). The first five of these benchmarks make use of different
types of rails, which are expected to present respectively 2D-springback (change in shape along
the cross section), 3D-springback (change in shape along the cross direction and curvature along
the longitudinal direction), warping (curvature along the longitudinal direction), and twisting (twist
angle along the longitudinal direction), and a combination of these effects. The sixth test is a panel
with a central depressed part, which will present a surface deflection near the indent and a large
shape deviation from the CAD geometry before and after trimming, as well as wrinkles on the
panel surface. The last two tests consider axisymmetric deep drawing processes leading to
wrinkling, earing, or rupture (limiting drawing ratio).
On each defined type of tool, 15 different forming conditions was considered, by choosing three
different blankholder pressures and five different materials (a mild steel, a high-strength steel, a
dual phase steel and two aluminium alloys), as shown in Table 2.
Table 2. Materials to be characterized and used for the benchmarks
Material Grade Thickness Provided b
Al allo 5xxx 5182-O 1 mm Pechine
Al allo 6xxx 6016-T4 1 mm Pechine
Mild steel DC06 0.7 mm ARCELOR
HSLA QSLE340 0.7 mm Cockerill-Sambre
Dual hase steel DP600 0.7 mm ARCELOR
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Fig.5 Representation of the eight experimental benchmark tests
Summary of Results:
A set of experimental benchmark tests for evaluating numerical methods are defined. Foreach
defined type of tool, 15 different forming conditions was examined and defined, by choosing three
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different blankholder pressures and five different materials (a mild steel, a high-strength steel, a
dual phase steel and two aluminium alloys)
Task 2: Carrying out the experimental benchmark tests and geometrical measurement of
the parts
The set of benchmark tests defined in task 1 were carried out, thus providing a comprehensive
database for the further evaluation of the software ability to predict forming defects
In order to ensure a high reliability of the results, each benchmark were carried out by several
partners. To avoid differences in tooling design and wear, all partners used new stamping tools, of
identical design, and produced by the same toolmaker. Furthermore, each contributing partner
performed five identical tests for each benchmark, in order to evaluate the consistency of the
results.
The pressed parts were thoroughly measured by each company performing the test, according to
the available facilities. For each part produced, experimental data e.g. the evolution of the forming
load vs. punch displacement, the thickness distribution along identified cross sections, and the
geometrical description of the part shape and defects were collected as reference data for
comparison with the results of numerical simulations. The measurements were obtained from
devices placed within the stamping tooling, the instrumentation of the press, and from
conventional metrology equipment, such as 3D co-ordinate measuring machines.
Any case of discrepancy were thoroughly analyzed and the incriminated tests were repeated with
the participation of other partners. This represents, of course, a considerable experimental effort,
since each test performed by a partner is necessitate the drawing and measurement of at least 75
press parts. Table 3 shows the tests that were carried out by the partners of the inter-regional
consortium.
Table 3. Participation of the inter-regional consortium to the experimental benchmarks
Benchmark No.Partner
1 2 3 4 5 6 7 8
ARCELOR x x x x
Cockerill-Sambre x x
DaimlerChrysler x x x
Volvo x x
Renault x x
Pechiney CRV x x x x x
FEUP x x x x
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NISSAN x x
PRESS GOGYO x x x x x x
TSUBAMEX x x x x
Summary of results:
The set of benchmark tests defined in task 1 were carried out to provide a comprehensive
database for the further evaluation of the software ability to predict forming defects.
In order to have reliable results, each benchmark was carried out by several partners. Mostly we
could have satisfactory results of benchmark tests. However, we observed there were some
scattering in results of aluminum. In Phase 2, we continuously pursuing a mechanism of the
causes.
Task 3: Standardization of input-output data for benchmark tests
The input output data utilised for simulating the forming processes and for evaluating the
numerical results should be standardized. In particular, the content of the input data, including the
forming condition and the tool geometry must be unified in order to prevent some errors that occur
frequently in the evaluation of the numerical methods. This task is closely related to the data
formats discussed in WP1.
Summary of results:
In order to standardize the input and output data, first input-output data format was specified for
simulation of the benchmarks and the tool geometry data (for punch, die, blankholder) was
distributed to the partners performing numerical simulations. About the most appropriate finite
element type and size, contact, strategy, tool description / discretization and dynamic parameters
were considered.
Task 4: Evaluation and improvement of the ability of numerical methods to predict forming
defects
The consortium members numerically simulated the benchmark tests proposed in task 1, by using
the finite element codes listed in Table 4. It is worth noting that these codes cover almost all
numerical strategies currently employed in the simulation of sheet metal forming (dynamic explicit,
static explicit, semi- or fully implicit, one-step methods, etc.). On the other hand, the set of codes
used by the consortium members include extensively used commercial codes like OPTRIS,
AUTOFORM, PAM-STAMP and LS-DYNA, as well as a few codes developed by academic or
research institutions belonging to the inter-regional consortium.
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Table 4. Participation of the inter-regional consortium to benchmark simulations
Benchmark No.Partner FE codes used for
simulations 1 2 3 4 5 6 7 8ARCELOR OPTRIS, AUTOFORM x x x x
Cockerill-Sambre OPTRIS x x
DaimlerChrysler LS-DYNA, INDEED x x x
Volvo LS-DYNA,
AUTOFORM
x x x x
Renault PAM-STAMP x x
Pechiney CRV OPTRIS x x x x
UTS OPTRIS x x x x x x xCNRS-LPMTM DD2IMP x x x
FCTUC PAM-STAMP, DD3IMP x x x
ESI OPTRIS x x x x x x x
AutoForm AUTOFORM x x x x
F.T.I. FAST Suite x x x x x x x x
NISSAN ITAS3D, AUTOFORM x x x x
PRESS KOGYO PAM-STAMP x x x x x x
Osaka Institute ITAS-Dynamic x x x x x
This provides an excellent background for a comprehensive and unbiased evaluation of the
ability of various types of numerical modelling to predict forming defects and for improving the
available numerical strategies. Each consortium partner develops the necessary interfaces
that is necessary for implementing the models of elastoplastic and friction behaviour selected
in WP3 and identified for the five materials. Furthermore, it was intended to perform - for a
limited number of the benchmark tests sensitivity studies concerning the influence of the
material and friction parameters and of the finite element mesh on the numerical results
obtained.
Summary of Results:
At first the procedure for evaluating the ability of a numerical method and software to predict each
type of forming defects were clearly defined. The simulations of the benchmark tests were carried
out. We could confirm validity of physical models developed in the WP3 and the accuracy.
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Workpackage 3: Selection of appropriate physical models and their identification
Scope and objectives
A variety of new sheet materials, such as high strength steels, aluminium alloys, titanium alloys,
copper alloys, laminated sheets and coated steel sheets, are on the market. New sheet materials
always cause technological difficulties in forming processes mainly because their mechanical and
tribological properties during sheet forming are unknown. 3DS could be a powerful tool to
overcome these difficulties by using simulations to establish optimum forming methods and
forming conditions. However, for the numerical simulation to provide realistic results, accurate and
efficient physical models are of primary importance.
Two major physical aspects are involved in sheet metal forming simulation. One is the
elastoplastic deformation of sheet metals and the other is the friction between the sheet and tools.
Both problems have been addressed by other research projects, too. The originality of our
approach is the attempt to obtain the best compromise between the accurate description of the
materials behaviour and the efficiency of the numerical simulations for steel and aluminium
sheets.
Description of the work
Task 1: Selection and identification of elastoplastic and friction models for the materials
and tools used in the benchmarks
The main constitutive models considered in this project is isotropic or anisotropic elasticity, initial
plastic orthotropy described by Hill48 model, isotropic and/or non-linear kinematic hardening,
rotation of the orthotropy axes at large deformations.
The initial anisotropy was determined by uniaxial traction and simple shear tests on specimens
oriented at different angles to the rolling direction. The deformation-induced plastic anisotropy was
characterized by first deforming large specimens in traction or simple shear, subsequently cutting
out small specimens at different angles to the preshear direction, and subjecting them to either
simple traction or simple shear. The results obtained was validated by using plane strain and
bulging experiments.
As far as friction is concerned, three different zones should be considered in the deep drawing of
sheets: the zone under the blank-holder, where the contact pressure is moderate and the relative
displacements between the sheet and the tools are large; the zone on the die radius, where the
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contact pressure is high and the relative displacements are large, while the friction phenomena
combine with plastic deformation; finally, the zone under the punch, where the pressure is low and
the relative displacements are small. Therefore, the friction tests developed in this task simulatesas close as possible the contact conditions on these three zones for the tooling, the materials, and
the blank-holding pressures used in the experimental benchmarks.
Summary of results:
The anisotropy of the elastic constants by tensile tests on very stiff machines and by other
non-destructive techniques were determined. Uniaxial tensile tests and/or simple shear tests in
various directions of the sheet plane was performed in order to determine the initial anisotropy and
the hardening under monotonic loading. Large-amplitude, cyclic simple shear tests for the
investigation of the kinematic hardening were performed. Sequences of simple shear and tensile
tests with intermediate change of the loading direction for the investigation of the distorsional
hardening were performed. The strain rate sensitivity was determined. Appropriate constitutive
models for the 5 materials by using the experimental result were identified.
the development of mathematical formulation for the evolution of deformation induced texture for
the metal with BCC Lattice, the rotation of principal axes of plastic anisotropy caused by
pre-straining in polycrystalline sheet metal and material parameter identification methods for
elastic / Crystalline Viscoplastic finite element analysis were carried out.
Task 2: Selection of effective numerical algorithms for implementing the physical models
into numerical codes
The numerical methods employed in numerical codes make use of various time-integration
schemes. To incorporate the elastoplastic and friction models developed in Task 1 into the
numerical methods tested by all consortium partners, robust time integration algorithms was
developed, checked on standard numerical benchmarks, and optimized. A special contribution
was brought by ESI and Autoform, who developed and optimized the implementation of the
material and friction models into the commercial code OPTRIS, respectively AUTOFORM, which
are used by several partners. The implementation of the material and friction models into the other
codes used for numerical simulation were assured by Volvo for LS-DYNA, DaimlerChrysler for
INDEED, Renault for PAM-STAMP, CNRS-LPMTM for DD2IMP, FCTUC for DD3IMP, FTI for
FAST Suite, NISSAN for ITAS3D and Osaka Inst. for ITAS-Dynamic; this implementation will be
made available for the other partners using the same codes.
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Summary of results:
Effective numerical algortithms were selected for implementing the physical models into numerical
codes. At the same time, development of mathematical formulation for the evolution ofdeformation induced texture for the metal with BCC Lattice, the rotation of principal axes of plastic
anisotropy caused by pre-straining in polycrystalline sheet metal and material parameter
identification methods for elastic / Crystalline Viscoplastic finite element analysis were carried out.
Task 3: Verification of the appropriateness of the selected physical models for predicting
forming defects
The accuracy of the simulation results and efficiency of computation for the physical models
selected in task1 and the numerical algorithms implemented in task 2 were evaluated by using
sensitivity tests on the benchmarks defined and carried out within WP2.
Summary of results:
The appropriateness of the selected physical models were validated by using sensitivity tests
defined and carried out within WP2. Aiming for improvement of physical model, we are
implementing the development of physical model in loading process in Phase 2.
3. Project Administration
3.1 Project Management Structure
The project management was organised such as to ensure an extensive international
collaboration with minimal administrative cost and efficient use of time and resources. The
Inter-regional management structure of the 3DS project is shown in Figure 9.
Both inter-regional and European project management are structured with a project co-ordinator, a
steering committee, a technical committee, and working package leaders.
Within the 3DS consortium, the Steering Committee has the overall responsibility of the project. It
consists of the Regional Co-ordinating Partners,with Famotik Co., Ltd. acting as Inter-regional
Co-ordinating Partner.
The technical management is carried out by the Technical Committee, who set the research
directions according to the objectives of 3DS, and by the Work Package Leaders , who gave
advice on current research and certify the quality of the partial and final reports. The resolutions of
the technical committee were decided by unanimity.
The personal composition of the steering and technical committees and the leadership of the work
packages (WPs) is as follows.
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3.2 Administrative Structure
The 3DS Steering Committee have met at least twice a year and the Consortium membersattended at least one of these meetings. The Technical Committee met several times when
necessary. If the committee members wanted to meet, meetings were held at any time. During
steering and technical meetings, report reviews were made in order to make sure that the
expected results are obtained and no obscure points are left unsolved.
In order to maintain a continuous contact between Task Leaders and partners involved in a
particular work, the Task Leaders organised so-called video conference at intervals of one or one
and a half months, in order to have a clear view of what is on the way and to avoid
misunderstandings about the goals and the delays. This was also avoid postponing the necessary
decisions up to the next meeting.
A general meeting of all consortium partners were held at every milestone of the project.
Figure 6. The 3DS Management Structure.
3.3 Communication Infrastructure
In the preparation of project, we exchanged information among partners through the network of
electric mail. This solution was fast and worked very well. However, once project was started, a
size of data include experimental data, presentation data were became large and we faced
difficulties to exchange such as large size of data.
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In order to solve such problems, we constructed common server called Project Extranet Server
that permits us to share and to manage information. This server consists of Cabinet for upload
and download experimental data, meeting minutes etc., Bulletin Board for communication amongpartner, Scheduler for notification of schedule, Circulation for circulate information among
partners, and Forum for discussion among partners. With this server, regardless of country,
partners could obtained necessary information at any time. It can be not exaggerate to say that
this server facilitate global communication, that is one of important issue in the international
collaboration research. Thus an excellent and efficient research work environmental was realized.
4. Consortium Composition
4.1 Regions involved and ICP/RCP
Regions Involved:Japan, EU, Canada, Switzerland
International Coordinating Partner (ICP): Famotik Co., Ltd.
Regional Coordinating Partners (RCP) :
Japanese Region: Famotik Co., Ltd.
European Union Region: ARCELOR
Canadian Region: Forming Technologies Incorporated
Swiss Region: AutoForm Engineering GmbH
4.2 Consortium Partners
[Canada Region]
Industrial Partners:
Forming Technologies Incorporated
[European Union Region]
Industrial Partners:
Cockerill-Sambre R&D (Belgium)
DaimlerChrysler AG (Germany)
ESI (France)
Pechiney CRV (France)
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Renault (France)
ARCELOR (France)
Volvo Car Corporation (Sweden)UTS S.p.A (Italy)
Academic Partners:
CNRS-LPMTM (France)
FEUP-DEMEGI (Portugal)
DEM-FCTUC (Portugal)
[Japan Region]
Industrial Partners:
FAMOTIK, Ltd.
NISSAN MOTOR Co., Ltd.
PRESS KOGYO Co., Ltd.
TSUBAMEX Co., Ltd.
Academic Partners:
Osaka Institute of Technology, Dept. of Mechanical Engng.
The University of Tokyo, Institute of Industrial Science
GSIS of Tohoku University
[Switzerland Region]
Industrial Partners:
AutoForm Engineering GmbH
5. Dissemination of results
In accordance with IPR and Consortium Collaboration Agreement(CCA), the results of 3DS will be
disseminated through presentation at conferences, seminars and workshop, as well as
publications in scientific journals. The following deliverables will be public; Models identification,
Friction coefficients, Benchmark results, physical models verification and physical model reports.
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*Note:
This final report is written by present ICP in Phase 2, Mr. Naomichi Mori of CIMTOPS Corporation.
Because the former ICP, Mr. Taizo Ono of Famotik. Ltd. faced severe company crisis and Famotikwas impossible to continue the project. Therefore, instead of Famotik, present ICP, CIMTOPS
Corporation took over ICP (include researchers).