Today the metal forming industry is making increasing use of simulation to evaluate the performing of dies, processes and blanks prior to building try-out tooling. Finite element analysis (FEA) is the most common method of simulating sheet metal forming operations to determine whether a proposed design will produce parts free of defects such as fracture or wrinkling.[1]

Crack in the vertical wall due to high tensile stresses, some small radius block the material flow and results in excessive thinning at that point usually more than 40% of the sheet thk. result in cracks. In some cases it may happen due to excessive blank holder pressure, which restrict the metal flow. Somewhere it might be due to wrong process design, like try to make a more deep draws in a single stage, which otherwise feasible only in two stages.[2]

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Springback is a particularly critical aspect of sheet metal forming. Even relatively small amounts of springback in structures that are formed to a significant depth may cause the blank to distort to the point that tolerances cannot be held. New materials such as high strength steel, aluminum and magnesium are particularly prone to springback.[3]

The first effort at simulating metalforming was made using the finite difference method in the 1960s to better understand the deep drawing process. Simulation accuracy was later increased by applying nonlinear finite element analysis in the 1980s but computing time was too long at this time to apply simulation to industrial problems.[citation needed]

Rapid improvements over the past few decades in computer hardware have made the finite element analysis method practical for resolving real-world metal forming problems. A new class of FEA codes based on explicit time integration was developed that reduced computational time and memory requirements. The dynamic explicit FEA approach uses a central different explicit scheme to integrate the equations of motion. This approach uses lumped mass matrices and a typical time step on order of millionths of seconds. The method has proved to be robust and efficient for typical industrial problems.[citation needed]

Inverse One-step methods compute the deformation potential of a finished part geometry to the flattened blank. Mesh initially with the shape and material characteristics of the finished geometry is deformed to the flat pattern blank. The strain computed in this inverse forming operation is then inverted to predict the deformation potential of the flat blank being deformed into the final part shape. All the deformation is assumed to happen in one increment or step and is the inverse of the process which the simulation is meant to represent, thus the name Inverse One-Step.

Incremental analysis has filled the role previously completed through the use of proof tools or prototype tools. Proof tools in the past were short run dies made of softer than normal material, which were used to plan and test the metal forming operations. This process was very time consuming and did not always yield beneficial results, as the soft tools were very different in their behavior than the longer running production tools. Lessons learned on the soft tools did not transfer to the hard tool designs. Simulation has for the most part displaced this old method. Simulation used as a virtual tryout is a metal forming simulation based on a specific set of input variables, sometimes nominal, best case, worst case, etc. However, any simulation is only as good as the data used to generate the predictions. When a simulation is seen as a "passing result" manufacturing of the tool will often begin in earnest. But if the simulation results are based on an unrealistic set of production inputs then its value as an engineering tool is suspect.

Recent innovations in stochastic analysis applied to sheet metal forming simulations has enabled early adopters to engineer repeat-ability into their processes that might not be found if they are using single sets of simulations as "virtual tryout".[7]

Chaboche type material models are sometimes used to simulate springback effects in sheet metal forming. These and other advanced plasticity models require the experimental determination of cyclic stress-strain curves. Test rigs have been used to measure material properties that when used in simulations provide excellent correlation between measured and calculated springback.[8]

Many metal forming operation require too much deformation of the blank to be performed in a single step. Multistep or progressive stamping operations are used to incrementally form the blank into the desired shape through a series of stamping operations. Incremental forming simulation software platforms addresses these operations with a series of one-step stamping operations that simulate the forming process one step at a time.[9]

Another common goal in design of metal forming operations is to design the shape of the initial blank so that the final formed part requires few or no cutting operations to match the design geometry. The blank shape can also be optimized with finite element simulations. One approach is based on an iterative procedure that begins with an approximate starting geometry, simulates the forming process and then checks deviation of the resulting formed geometry from the ideal product geometry. The node points are adjusted in accordance with the displacement filed to correct the blank edge geometry. This process is continued until the end blank shape matches the as-designed part geometry.[10]

Metal forming simulation offers particular advantages in the case of high strength steel and advanced high-strength steel which are used in current day automobiles to reduce weight while maintaining crash safety of the vehicle. The materials have higher yield and tensile strength than conventional steel so the die undergoes greater deformation during the forming process which in turn increases the difficulty of designing the die. Sheet metal simulation that considers the deformation of not only the blank but also the die can be used to design tools to successfully form these materials.[11]

Tata Motors engineers used metal forming simulation to develop tooling and process parameters for producing a new oil pump design. The first prototypes that were produced closed matched the simulation prediction.[12]

Nissan Motor Company used metal forming simulation to address a tearing problem in a metal stamping operation. A simple simulation model was created to determine the effect of blank edge radius on the height to which the material could be formed without tearing. Based on this information a new die was designed that solved the problem.[13]

In metal forming simulation, the forming of sheet metal is simulated on the computer with the help of special software. Simulation makes it possible to detect errors and problems, such as wrinkles or splits in parts, on the computer at an early stage in forming. In this way, it is not necessary to produce real tools to run practical tests. Forming simulation has become established in the automotive industry since it is used to develop and optimize every sheet metal part.

To illustrate the metal forming process, there must be a model of the real process. This is calculated in the software using the finite element method based on implicit or explicit incremental techniques. The parameters of the model must describe the real process as accurately as possible so that the results of the simulation are realistic.

The typical parameters for forming simulation are, for example, part and tool geometry, material properties, press forces and friction. The simulation calculates stresses and strains during the forming process. In addition, simulations allow for the recognition of errors and problems (e.g. wrinkles or splits) as well as results (e.g. strength and material thinning). Even springback, the elastic behavior of material after forming, can be predicted in advance. Forming simulation also provides valuable information about the influence of process variations on stamping robustness.

Forming simulations are used throughout the entire process chain of sheet metal forming. The simulation allows a part designer to estimate the formability of a sheet metal part already during the design phase, which results in the design of a part which is easy to produce. A process engineer can already assess the process during the planning phase and optimize various alternatives using the simulation, which can subsequently reduce the fine tuning of a forming tool. Finally, regarding the fine tuning of a forming tool, simulation can provide useful information on how an existing, not yet fully functioning tool must be adjusted. It is also possible to see how the process parameters must be adjusted in order to guarantee optimal drawing results.

Metal forming simulation enables the fast review of several alternative concepts for quality and cost improvements, which results in huge cost and time savings. Furthermore, simulating the forming process improves development and planning reliability. The number of tool tryouts is reduced and tryout time is shortened. Metal forming simulation leads to the highest quality in part and tool design as well as maximum reliability in production.

ESI PAM-STAMP gives you the ability to address sheet metal formability challenges from the design of parts and tooling to part production with a single tool. Validate the forming of individual panels and even help validate the assembly of closure panels, such as doors. Develop and validate key manufacturing and joining processes, virtually, to assure production capability of parts, sub-assemblies, and assemblies for all sheet metal parts, simple to complex, conventional steel to advanced lightweight sheet metals.

In response to market demand to form complex parts with small bend ratios, PAM-STAMP offers accurate tube bending simulation with realistic tool modeling and behavior for better forming results to avoid downstream problems. be457b7860

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