Simulation Techniques in Manufacturing Technology Lecture 4 · Simulation Techniques in...
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Sheet Metal Forming II
Simulation Techniques in Manufacturing Technology
Lecture 4
Laboratory for Machine Tools and Production Enginee ring
Chair of Manufacturing Technology
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. F. Klocke
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Economical aspects of process modelling4
Case Study3
Simulation of Sheet Metal forming2
Introduction1
Outline
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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
� 1909: Introduction of the Ritz solution method
� 1915: Introduction of the weighted residual solution method by Galerkin
� 1943: Introduction of the variation solution method by Courant
� 1960: The terminology Finite Element Method first used by Clough
� ab 1970: Development of the first commercial FE-software
Source: Domenico Fetti, Columbia Encyclopedia
time
Archimedes
Ritz
Galerkin
Courant
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Why process modelling?
Car BodyTime Cost
Quality
Increase quality
Apply new materials(Al, Mg, …)
Use material moreefficiently
Reduction of toolcost
Reduction of leadtime
Reduction of timerequired for training
Increase reliabilityof production
Manufacture complex parts
Reduction of pre production trials
Source: BMW
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Integration of process modelling into the process c hain
Source: BMW
Designof car
exterior
Part design
Partproduction
Means of production Tool manu-facturing and testingTool designPlanning
Sheet metal forming simulationPart evaluation Process optimisation
Sof
twar
e so
lutio
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pplic
atio
nP
roce
ss c
hain
Methods applied:- 2D modelling- one-step modelling- modelling with membrane elementsShort computation time with sufficient precision
Methods applied:- Simulation with membrane elements- Simulation with shell elements
High Precision within acceptable computation times
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Economical aspects of process modelling4
Case Study3
Simulation of Sheet Metal forming2
Introduction1
Outline
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Disadvantages:
� difficult selection of cross sectionsto be modelled
� less accurate results
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:
� reduced computation time
� less sensitive to quality of inputdata
� usually less input data required
Source: BMW / Fontana Pietro SPA
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One-step simulation:
� Isopunch
� SIMEX
� Corps
� AutoForm Onestep
� ...
Advantages:
� reduced computation time
� usually less input data required
� suitable tool for part evaluation
Disadvantages:
� decreasing significance due to increasing computing power
� still not very accurate
Source: BMW
Commercial FE codes for sheet metal forming
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Model with membrane elements:
� AutoForm Incremental
� Abaqus
� ...
Advantages:
� acceptable computation time
� suitable tool for part evaluation
� suitable for process optimisation
� basically accurate results
Disadvantages:
� long computation time
� problems when severe bending occurs
� not accurate enough in predicting wrinkles
� requires high quality input dataSource: BMW
Commercial FE codes for sheet metal forming
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Model with shell elements:
� PAM-STAMP
� Optris
� DYNA-Form
� Indeed
� ...
Advantages:
� state of the art tools for processoptimisation
� very accurate results
Disadvantages:
� long computation time leads to long response time
� requires high quality input data
Source: BMW
Commercial FE codes for sheet metal forming
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Economical aspects of process modelling4
Case Study3
Simulation of Sheet Metal forming2
Introduction1
Outline
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Procedure of FE-Analysis
CAD-model
Idealization
Diskretization
Boundary conditions
FE-Analysis
Interpretation of the results
Pre-processor
Solver
Post-processor
====
23
13
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22
11
13
23
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2212
1211
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γγγεε
τττσσ
G
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GG
GG
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Material Laws
� Modelling of the material behavior based on mathematical material laws
� Deduction of the modelling parameters from experimental data:
– Elastic material behavior: Young’s Modulus, Poisson’s ratio, elastic anisotropy
– Plastic material behavior: flow curve, strain hardening parameter, plastic anisotropy
� Usage of ideal-plastic material models are mostly sufficient for bulk forming
� Usage of elastoplastic material models in sheet metal forming simulations
� Consideration of plane anisotropy for sheet metal forming simulations
Elastic
σ
ϕIdeal-plastic
σ
ϕ
Plastic withstrain hardening
σ
ϕElastoplastic withstrain hardening
σ
ϕ
Low accuracy / low calculation time
High accuracy / high calculation time
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Friction laws in metal forming� Coulomb friction:
� Shear friction:
with
� Wanheim and Bay developed a more general friction law with a continuous transition of the two friction laws mentioned above:
σN – Normal stress
τR – Shear stress
µ,m – Friction coefficients
f – Friction factor
α – Ratio of the contact areas
Coulomb friction
Shear friction
Reality
Orowan
Shaw / Wanheim und Bay
Reality
Nσ
Nσ
Rτ
Rτ
NR σµτ ⋅⋅⋅⋅====
kmR ⋅⋅⋅⋅====τ3fk
k ====
kfR ⋅⋅⋅⋅⋅⋅⋅⋅==== ατ
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Part Evaluation: One step method
Steps:
1) Create mesh from 3DCAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results
Source: BMW
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Part Evaluation: One step method
Source: BMW
Steps:
1) Create mesh from 3DCAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results
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Source: BMW
Steps:
1) Create mesh from 3DCAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results
Part Evaluation: One step method
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Source: BMW
Steps:
1) Create mesh from 3DCAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results
Part Evaluation: One step method
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Source: BMW
Steps:
1) Create mesh from 3DCAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results
Part Evaluation: One step method
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Source: BMW
Steps:
1) Create mesh from 3DCAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results
Part Evaluation: One step method
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Contact stress distribution for circular tool geome try
drawing direction
Contact concentration
FSt,max = 64,5 kN
0
400
100
200
300
0
400
100
200
300
Contact-stressesσ
N / MPa
0
70
0 35Stroke s / mm
Pun
ch fo
rce
FS
t/ k
N
A-A
A-A
Anisotropy effect
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Alternative tool geometries
Lamé (a = 10 mm; b = 8 mm; n = 3)
Lamé (a = 10 mm; b = 8 mm; n = 4)
0
400
100
200
300
ContacktstressesσN / MPa
Lamé (a = 10 mm; b = 7 mm; n = 3)
Lamé (a = 12 mm; b = 7 mm; n = 3)
0
70
0 35Stroke s / mm
Pun
ch fo
rce
FS
t/ k
N
FSt,max = 64,5 kNFSt,max = 61,8 kNFSt,max = 61,8 kNFSt,max = 60,1 kNFSt,max = 63,1 kN
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Reduction of stress concentration and wear using th e Lamé-curve
Contact stressσN / MPa
Areas with increased
contact stress
Circle-curve Lamé-curve
gradually increasing
contact stress
direction of pull direction of pull
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Process optimisation: Forming process
CAD-datatool & blank
Meshing
Process boundary conditions
Contact formulation
GENERIS
Material-data
PAM-STAMP Input file
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Process optimisation: Forming sequence
Source: BMW
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Case study: Process optimisation by improved tool d esign
Source: BMW
Part geometry Workpiece end geometry Initial workpiec e geometry
Tool geometryTool geometry (cut view)
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Process optimisation: Forming sequence
Source: BMW
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Source: BMW
Process optimisation: Forming sequence
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Source: BMW
Process optimisation: Forming sequence
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Source: BMW
Process optimisation: Forming sequence
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Source: BMW
Process optimisation: Forming sequence
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Source: BMW
Process optimisation: Forming sequence
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Case study: Evaluation of wrinkling
distribution of effective strain during and after the drawing process
Source: BMW
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Process optimisation: Evaluation of wrinkling
Source: BMW
distribution of effective stress during and after the drawing process
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Process optimisation: Comparision between simulatio n and real part
Source: BMW
wrinkling
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Process optimisation: Comparision between simulatio n and real part
Source: BMW
rupturing
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Economical aspects of process modelling4
Case Study3
Simulation of Sheet Metal forming2
Introduction1
Outline
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Modelling sheet metal forming: Quality of the compu ted results
0+springback
++++wrinkles
+++rupture
Quality
qualitatively quantitatively
Result
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Flow chart of a modelling project
Partgeometry
Materialselection
Tools(CAD)
Processparameters
SimulationStart tool
design
no
yes
Part design Boundary Conditions Simulation
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Effort for a sheet metal modelling project
Change of responsible effort CAD effort Simulation
Process parameters (friction, beads, ...)
Process design ---- 1h --3h
die setup (blank holder, etc. ...)
Process design 1d -- 1w 3h -- 1d
Material quality and thickness
Body design ---- 1h -- 3h
Part geometry Body design 1d --1w 3h -- 1d
Total effort for a medium sized part: Usually 2 wee ks
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Preprocessing effort for a modelling project in she et metal forming
1993 2009
1W
2 W
3 W
Effort for preprocessing
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Development of computing power and computation time
100%
1993 2009
20%
Increase of computing power
1993 2009
50h
15h
Reduction of computation time for a large car body
part
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Development of hardware cost
1993
Hardware cost
2009
100 %
< 1 %
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Prerequisites for the industrial application of pro cess modelling
Time: Cost: Quality:
Short responsetimes
Low projectcost
Reliable results
Integration into the process chain of a car body
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Simulation of crashworthiness for the Ford Explorer (LS-Dyna)
Source: Livermore Software Technology