Advance in FEM Simulation and its Related Technologies in Sheet Metal Forming

Makinouchi, Akitake; Teodosiu, Cristian; Nakagawa, Takeo

doi:10.1016/s0007-8506(07)63246-6

Cited by 52 publications

(29 citation statements)

References 6 publications

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“…The advantage of the FE simulation in sheet metal forming consists of the fact that manufacturing processes of complex parts can be calculated and thus process limits for a set of parameters be can defined [13].…”

Section: Numerical Simulationmentioning

confidence: 99%

Numerical simulation to improve robustness in sheet metal forming process chains

Hagenah¹,

Geiger²,

Merklein³

2013

AIP Conference Proceedings

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Abstract. The paper will present developments towards the improvement of the robustness of sheet metal forming process chains. The possibilities and challenges will be demonstrated using two examples. Firstly, the effect of heat treatment to precipitation hardened aluminum sheet metals in order to enlarge the process window for deep drawing operations will be discussed. Numerical simulation can be used to predict the effects of the heat treatment. Using more sophisticated approaches the heat treatment layout and its effects on the forming process can be computed and predicted. Thus the process window can be enlarged and in consequence the process chain will receive an increased robustness. Secondly the integrated tube and sheet hydroforming process that also includes joining operation will be used as an example of the positive impact numerical simulation can have on complex process chains. This highly integrated process chains needs carefully designed tools that ensure robust production. Furthermore, several effects occurring during the forming operations are difficult to understand since the process cannot be stopped at arbitrary moments or easily investigated in situ. The needed understanding and therefor the mandatory input for successful and robust process design has to be derived from advanced numerical models and the according simulation runs.

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Section: Numerical Simulationmentioning

confidence: 99%

Numerical simulation to improve robustness in sheet metal forming process chains

Hagenah¹,

Geiger²,

Merklein³

2013

AIP Conference Proceedings

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“…The simulations have contributed to a significant decrease in the use of try-out tools [1], thus decreasing both lead time and costs. The sheet-metal-forming simulations are today widely used in the automotive industry [2], [3]. However, prediction of springback is not accurate enough to be fully reliable, and therefore experimental tests are still required, to a large extent in order to evaluate the deviation in geometry due to the springback.…”

Section: Introductionmentioning

confidence: 99%

“…However, as this material is used to a small extent in the automotive industry and it therefore was of interest to include it in this study. 3 The experiments were performed under controlled conditions. In order to verify the simulation results, these were compared to experimental results after both the blank holder closing (binder wrap) and the forming/springback.…”

Section: Introductionmentioning

confidence: 99%

Numerical and experimental evaluation of springback in a front side member

Andersson

2005

Journal of Materials Processing Technology

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Changes in geometry after springback are a major problem for the automotive industry. In order to make adjustments of the part to be formed, extra processes are needed. Since their implementation is both time-consuming and expensive, the industry would stand to gain if geometrical changes could be predicted at the time that the tool is being designed. Today, sheet-metal-forming simulations are, to a large extent, used to evaluate the forming process. Reliable results of the forming process can be obtained regarding, for instance, thinning, forces and fractures, but prediction of springback is not accurate enough to be fully reliable. Furthermore, the introduction of new, high strength steels, such as TRIP steels, emphasize the springback problem even more. This demands an increased ability to accurately predict the outcome of the forming process.In this study a part of an automotive side front section (front side member inner) was studied and a comparison both regarding material behaviour and of accuracy of the FE simulations was made. Mild steel, Rephos steel and TRIP700 were compared both experimentally and numerically. The results showed that TRIP steel has a significantly larger springback than the other materials. Furthermore, the FE simulations overestimate the twisting in this part for all materials, with the TRIP material showing the largest deviation between the experiments and the simulations. The prediction of punch forces was, however, accurate for all materials.

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Section: Introductionmentioning

confidence: 99%

“…The most significant advantages compared with try-out methods are the time and cost reductions. The use of sheet-metal-forming simulations in the automotive industry has been described by Makinouchi (1996) and Makinouchi et al (1998).The use of sheet-metal-forming simulations enables the possibility to visualize the forming process. With the simulation technique, it is possible to animate the process and thereby analyse it during the punch stroke.…”

mentioning

confidence: 99%

Information exchange within the area of tool design and sheet-metal-forming simulations

Andersson¹

2001

Journal of Engineering Design

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Link to publicationCitation for published version (APA): Andersson, A. (2001). Information Exchange within the area of tool design and sheet-metal-forming simulations. Journal of Engineering Design, 12(4), 283-291. DOI: 10.1080/09544820110085933 General rights Copyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright owners and it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights.• Users may download and print one copy of any publication from the public portal for the purpose of private study or research.• You may not further distribute the material or use it for any profit-making activity or commercial gain • You may freely distribute the URL identifying the publication in the public portal Information exchange within the area of tool design and sheet-metal-forming simulations A. ANDERSSON † ‡* Today, shortened lead-times in the automotive industry have raised requirements on rapid information exchange. The increased use and access to the Internet have created possibilities to transfer information to people independent of location. This development, together with the increased speed in the portable computer technology, has opened possibilities for bringing results from sheet-metal-forming simulations directly to the customer. Previously, the results were presented with pictures; now it is possible to use animations. The only requirement is to have access to a post-processor or a viewer that is powerful enough to handle the results. The advantage with animated results is the improved possibilities to follow the sheet-metal-forming process.In this project, the methodology for reporting results from sheet-metal-forming simulations at Volvo Cars Body Components is studied. A potential for improvement would be possible if the reporting procedure is changed from paper copies to a database structure. In the database the results should be stored as files with animated results that the user is able to rotate and zoom. This methodology will contribute to faster and more accurate decisions because it will be based on current information and the user could easily analyse the results without access to special programs. IntroductionSheet-metal-forming simulations have become more common in the automotive industry during the past decade and are efficient tools for many applications. The most significant advantages compared with try-out methods are the time and cost reductions. The use of sheet-metal-forming simulations in the automotive industry has been described by Makinouchi (1996) and Makinouchi et al. (1998).The use of sheet-metal-forming simulations enables the possibility to visualize the forming process. With the simulation technique, it is possible to animate the process and thereby analyse it during the punch stroke. If the same analysis is performed in a real tool, the punch stroke would be stopped at different heights and both material and time would be waste...

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Advance in FEM Simulation and its Related Technologies in Sheet Metal Forming

Cited by 52 publications

References 6 publications

Numerical simulation to improve robustness in sheet metal forming process chains

Numerical simulation to improve robustness in sheet metal forming process chains

Numerical and experimental evaluation of springback in a front side member

Information exchange within the area of tool design and sheet-metal-forming simulations

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