U pper/Low erBound M ethods Finite D ifference M ethods Finite Elem entMethods Boundary Elem entMethods Finite Volum e M ethods M eshless M ethods Satic Implicit Static Explicit Dynamic Explicit Smooth Particle Hydrodynamics Element Free Galerkin Method Moving Least Square Method Approximation Reproducing Kernel Particle Method Possible simulation techniques in Possible simulation techniques in metal forming metal forming
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Satic Implicit Static Explicit Dynamic Explicit Smooth Particle Hydrodynamics Element Free Galerkin Method Moving Least Square Method Approximation Reproducing.
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Upper/Lower Bound Methods
Finite Difference Methods
Finite Element Methods
Boundary Element Methods
Finite Volume Methods
Meshless Methods
Satic Implicit
Static Explicit
Dynamic Explicit
Smooth Particle Hydrodynamics
Element Free Galerkin Method
Moving Least Square Method Approximation
Reproducing Kernel Particle Method
Possible simulation techniques in metal Possible simulation techniques in metal formingformingPossible simulation techniques in metal Possible simulation techniques in metal formingforming
Modular Structure of Forming Modular Structure of Forming ProcessesProcessesModular Structure of Forming Modular Structure of Forming ProcessesProcesses
reference: K. Lange, reference: K. Lange, StuttgartStuttgartreference: K. Lange, reference: K. Lange, StuttgartStuttgart
FUNCTIONAL REQUIREMENTS
PART GEOMETRY(ASSEMBLY READY)
PART DESIGN FOR PROCESSEXPERIENCE BASED
PRELIMINARY DIE DESIGNEXPERIENCE BASED
SELECT PROCESS/MACHINEVARIABLESMODIFY DIE/PART
DESIGN
VERIFY DIE DESIGN & PROCESS VARIABLES
DIE DESIGN ANDPROCESS VARIABLES
ACCEPTABLE
ANALYZE DIE DESIGN FOR STRESSES SHRINKAGE AND PROCESS CONDITIONS
PREPARE DRAWINGS AND MACHINE DIES
INSTALL DIES AND SELECT MACHINES PARAMETERS
START FORMING PROCESS
FEM PROGRAM FOR METAL
DATABASE WITH DIE/MATERIAL PROPERTIES
YES
NO
Product and process design for net shape Product and process design for net shape manufacturingmanufacturingProduct and process design for net shape Product and process design for net shape manufacturingmanufacturing
NameName Manufacturer, countryManufacturer, country TypeType ApplicationApplication
ABAQUSABAQUS HKS, USAHKS, USA implicitimplicit generally, non-lineargenerally, non-linear
MARCMARC MARC, USA/NL. DMARC, USA/NL. D implicitimplicit generally non-lineargenerally non-linear
NIKE 3DNIKE 3D LSTC, USALSTC, USA implicitimplicit generally non-lineargenerally non-linear
LARSTRANLARSTRAN LASSO, DLASSO, D implicitimplicit generally non-lineargenerally non-linear
INDEEDINDEED INPRO, DINPRO, D implicitimplicit sheet metal formingsheet metal forming
ITAS3DITAS3D Prof. Nakamachi, JProf. Nakamachi, J explicit, staticexplicit, static sheet metal formingsheet metal forming
Be First to Market with Better and Cheaper Products !
Less Fine Tuning:• improved quality• less invisible defects
Shorter Development Time:• less trial and error• less blocking of production line• optimized for available press• less visible defects
AdditionalAdditional Benefits of Simulation Benefits of Simulation
Other benefits:• reduce number of mfg stages• more insight into mfg process• less machining operations• expand state of the art• more successful bids
Optimization during product life time:• extend die life• minimize material scrap• optimize process conditions• optimize press capacity utilization
simulation
CustomerSpecs
Design &Tool Dev.
PrototypeTesting
Pilot Stage
MassProduction
Reduce Costs during Mass Production !
Why SimulationWhy Simulation
• Reduce Time to MarketReduce Time to Market
• Reduce Cost of Tool DevelopmentReduce Cost of Tool Development
• Predict Influence of Process ParametersPredict Influence of Process Parameters
• Reduce Productions CostReduce Productions Cost
• Improve Product QualityImprove Product Quality
• Better Understanding of Material Better Understanding of Material BehaviorBehavior
• Reduce Material WasteReduce Material Waste
Manufacturing ResultsManufacturing Results
• Accurately predict the material flowAccurately predict the material flow• Determine degree of filling of the swage or dieDetermine degree of filling of the swage or die• Accurate assessment of net shapeAccurate assessment of net shape• Predict if laps or other defects existPredict if laps or other defects exist• Determine the stresses, temperatures, and Determine the stresses, temperatures, and
residual stresses in the work piece.residual stresses in the work piece.• Determine optimal shape of preformDetermine optimal shape of preform
Material BehaviorMaterial Behavior
• Determine material properties such as grain sizeDetermine material properties such as grain size• Determine local hardnessDetermine local hardness• Predict material damagePredict material damage• Predict phase changes and compositionPredict phase changes and composition• Simulate the influence of material selectionSimulate the influence of material selection
Tool ResultsTool Results
• Determine the forming loadsDetermine the forming loads• Determine the stresses in the toolsDetermine the stresses in the tools• Evaluate tool wear or fatigueEvaluate tool wear or fatigue• Simulate the influence of lubricationSimulate the influence of lubrication• Optimize multi-tool processOptimize multi-tool process
Simulation allows you to capture behavior that can not be readily measured – providing deeper insight into your manufacturing processes