Virtual tool reworking: New strategies in die design using finite element forming simulations

Lingbeek, R.A.

doi:10.3990/1.9789077172384

Cited by 4 publications

(12 citation statements)

References 44 publications

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“…The iterative spotting steps performed during the die try-out aim to homogenize the contact pressure within the die, to compensate for the fact that the elastic deformation is unknown [1]. Different methods for analysis and virtual rework of tool structures and surfaces, including the combination of structural behaviour with sheet metal forming simulations are described in [2]. The results show that the elastic deformation of the tools changes the blank draw-in significantly, leading to considerable changes in the product's quality measures [2].…”

Section: Introductionmentioning

confidence: 99%

“…Different methods for analysis and virtual rework of tool structures and surfaces, including the combination of structural behaviour with sheet metal forming simulations are described in [2]. The results show that the elastic deformation of the tools changes the blank draw-in significantly, leading to considerable changes in the product's quality measures [2]. Nevertheless, many of the methods suggested to combine the structural analysis and forming simulation into one FE-model lead to large models, which are time-consuming to solve when scaled to industrial dies.…”

Section: Introductionmentioning

confidence: 99%

“…The models that enable predicting the elastic deformations of dies can also be used to improve their structure using, for example, topology optimization [1]. Nevertheless, reliable results require accurate plasticity and the friction models, as pointed out in [2,3].…”

Section: Introductionmentioning

confidence: 99%

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Considering the stiffness of the forming tools in the numerical analysis of the ironing process

OLIVEIRA

2023

Materials Research Proceedings

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Abstract. Ironing can occur in cylindrical cup drawing whenever the thickness of the drawn flange is larger than the gap between the punch and the die. This is particularly relevant for materials that present r-values lower than 1.0, such as the aluminium alloys, since they tend to present more thickening of the flange. The aim of this study is to evaluate numerically the impact of the elastic deformation of the forming tools on the final cup geometry, i.e., the earing profile and the evolution of thickness along the circumferential direction, at different heights. Different contact conditions are also analysed since they strongly affect both the thickness strain and the earing profile. The process conditions considered are the ones from EXACT, the ESAFORM Benchmark 2021, enabling the comparison with experimental results. Considering the deformation of the forming tools mainly impacts the ironing stage, enabling predicting wall thickness values larger than the gap between the punch and the die.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Considering the stiffness of the forming tools in the numerical analysis of the ironing process

OLIVEIRA

2023

Materials Research Proceedings

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“…Previous research and experience points to many advantages if sheet metal forming is simulated with elastic dies [1][2][3][4][5][6][7][8]. Some areas that are enabled by simulations with elastic dies are virtual spotting, improved digital twins, and improved production support.…”

Section: Introductionmentioning

confidence: 99%

Three Industrial Cases of Sheet Metal Forming Simulations with Elastic Dies

Pilthammar,

Sigvant,

Islam

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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Previous research and experience points to many advantages if sheet metal forming is simulated with elastic dies. Some areas that are enabled by simulations with elastic dies are virtual spotting, improved digital twins, and improved production support. A promising method was selected from the literature, and after important modifications it is deemed to be fast and robust for simulating industrial sized dies. The method consists of meshing die solids with a coarse mesh to represent the structural behaviour of the die. The forming surfaces are then represented by a fine shell mesh connected to the solid mesh by tied contacts with an offset. With additional modifications to reduce solver time this yields a robust and flexible way of modelling sheet metal forming with elastic dies. There is an increase in preprocessing and simulation time compared to using rigid tools, but industrial dies can now be modeled within an hour and solved within a working day. It is also easy to update the model by replacing separate parts such as die solids or forming surfaces. One of the main criteria in favor of the selected approach is the realistic modeling of blankholder and cushion systems. In this paper simulations of three industrial cases are demonstrated: one case of virtual die spotting and two cases of production support. The three cases demonstrate the importance and potential of using elastic dies during virtual die tryout, production support, and for cases like digital twins and production control.

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“…Another reason is the lack of die CAD models before the later stages of stamping projects. Previous research during the last couple of decades indicated large benefits if elastic dies and presses are included in SMF simulations [1][2][3][4][5][6][7][8]. The benefits of simulations with elastic tools are also seen in related manufacturing techniques using dies and presses.…”

Section: Introductionmentioning

confidence: 99%

An overview of Methods for Simulating Sheet Metal Forming with Elastic Dies

Pilthammar,

Sigvant,

Islam

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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Sheet metal forming (SMF) simulations are traditionally carried out with rigid active forming surfaces. This means that the elasticity and dynamics of presses and die structures are ignored. The only geometries of the tools included in the simulations are the active forming surfaces. One reason for this simplification is the large amount of computational power that is required to solve finite element (FE) models that incorporates elastic stamping dies. Another reason is the lack of die CAD models before the later stages of stamping projects. Research during the last couple of decades indicated potential large benefits when including elastic dies in SMF simulations. For example, for simulating die try-out or for Digital Twins of presses and dies. Even though the need and potential benefits of elastic dies in simulations are well known it is not yet implemented on a wide scale. The main obstacles have been lacking data on presses and dies, long simulation times, and no standardized implementation in SMF software. This paper presents an overview of existing methods for SMF simulations with elastic dies and discuss their respective benefits and drawbacks. The survey of methods shows that simulation models with elastic tools will be needed for detailed analyses of forming operations and also for purposes like digital twins. On the other hand, simplified and robust models can be developed for non-FEA users to carry out simple one-step compensation of tool surfaces for virtual spotting purposes. The most promising and versatile method from the literature is selected, modified, and demonstrated for industrial sized dies.

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Virtual tool reworking: New strategies in die design using finite element forming simulations

Cited by 4 publications

References 44 publications

Considering the stiffness of the forming tools in the numerical analysis of the ironing process

Considering the stiffness of the forming tools in the numerical analysis of the ironing process

Three Industrial Cases of Sheet Metal Forming Simulations with Elastic Dies

An overview of Methods for Simulating Sheet Metal Forming with Elastic Dies

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