sheet metal forming simulation for light weight vehicle development
TRANSCRIPT
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Sheet Metal Forming Simulation for Light Weight Vehicle Development
Die Design & Simulation Software Experience Arthur Tang May 29, 2013
Grand Rapids, MI
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Industry Demand for Fuel Efficient Vehicles
• The Obama administration issued the final version of new rules that require automakers to nearly double the average fuel economy of new cars and light trucks by 2025.
• Currently, the CAFE (Corporate Average Fuel Economy) is around 29 MPG.
• New requirements is 36.6 MPG by 2017 / 54.5 MPG by 2025 。
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Fuel Efficient Vehicles – Possible Solutions
• Develop Small / Mini Cars – Not a good solution!
• Develop New / Alternative Energy Cars – Cost Increase, possible Weight Increase
• Reduce Vehicle Weight , Raise CAFÉ – Vehicle design optimization – Vehicle manufacturing optimization – Use Super High Strength Steel and/or Light Weight Materials
• Requirements to Develop Simulation Technology to support the overall weight reduction requirements – Must resolve Springback issues , in order to use more high strength steel
or use higher strength steel – Use Hot Forming approach to control Springback concerns in order to use
Super High Strength Steel, support 3rd Generation High Strength Steel – Implement Die Design Optimization simulation technology to
support various issues of die design
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Sheet Metal Forming Simulation Technology History and Challenges
• 1980s – Global OEMs and Steel / Alumini producers started the development of sheet metalforming simulation technology – Using Static Non-Linear FEA approach, Implicit Solution – After 10 years R & D, not practical to implement support
production
• 1993 – NUMISHEET1993, a international conference with focus on benchmarking sheet metal forming simulation technology – Adopted Dynamic Non-Linear FEA approach, Explicit
Solution – DYNAFORM, PAM/STAMP & AUTOFORM and various
commercial software packages were developed on this platform
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Sheet Metal Forming Simulation Technology History and Challenges
• Beginning of 2000s –Global OEM established the Virtual Trial Out process to replace traditional hardware trial out
• Late 2000s – Global tooling Industry adopted Virtual Trial Out process
• New and Future Challenges – Springback and Springback Compensation for Super High
Strength Steel – Support Hot Forming and Alternative Forming Technology – Die Face Optimization – Accurate Solution using New Computing Platform, Material
Utilization, etc.
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Virtual Tryout Simulation Methodology
Die Face Engineering and Formability
Simulation Technology and Methodology
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Product Design Reverse Trimming
Tip to Stamping Position
Binder Generation Addendum Calculation Addendum Generation
Die Face Engineering
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Draw Binder Wrap Trimming
Flanging Springback
Formability Simulations
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Die Face Engineering & Formability Example
Simulation Reliability could be examined per Comparison with hardware
Blank Material Draw-in
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DFE - Tipping (Auto and Manual)
Tip the part along X axis 80 degrees relative to the automatic tipping center
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DFE - Inner Fill
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DFE - Binder Creation
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DFE - Inner Addendum Creation
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DFE - Outer Addendum Creation
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DFE - Addendum Profiles Adjustment
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DFE - Binder / Addendum Trimming
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Die Face Established – CAD Surfaces
NURBS CAD Surfaces were generated same quality of the Product Design
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Generate Mesh for Formability Simulation
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Drawbead layout & Simulation Setup
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Simulation Result - FLD
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Simulation Result - Thinning
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Simulation Result - Draw In
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Simulation Result - Skid Mark
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Reliable Springback Simulation Requirement – Geometry Beads
Geometry Bead Generation and Line Bead Conversion to Geometry Bead
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Geometry Draw Beads – Parametrically Defined
Round Bead Square Bead
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Line Bead conversion with Geometry Bead
Section cut
Male Bead & Female Bead Additional discussion on Slide 72
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Round Bead
Male side Female side
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Springback Prevention in Product Design Stage
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Flanging – without darts
Flanging – with darts
Springback Prevention in Design- Case Study
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Spring Back – Flange without Darts, Right Side
Section cut starts 9mm from edge
Then 54mm interval through the panel
Blue: Product Green: Panel with spring back
Section Cut at the Darts
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0.261
0.354 0.196
0.221 0.141 0.090
0.417 0.140 0.679
0.030 0.007
0.086
0.141 0.215
0.864 0.422 0.963 0.939 0.486 0.130
0.172
0.391 0.159
0.233
0.194 0.111
0.517 0.286 0.792
0.123 0.103
0.120
0.163 0.159
0.773 0.376 0.908 0.850 0.389 0.150
Positive deviation (mm) Positive deviation (mm) Section line number
#1
Distance from edge
9mm
#2 63mm #3 117mm
#4 171mm
#5 225mm
#6 279mm
#7 333mm
#8 387mm
#9 441mm #10 495mm #11 549mm #12 603mm
#13 657mm #14 711mm #15 765mm #16 819mm
#17 873mm
#18 927mm #19 981mm
#20 1035mm
At tips of section lines At tips of section lines
Springback at Sections
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Deviation Comparison – Sums of Both Sides
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
2.8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
With Dart Design - Red
Dev
iatio
n (m
m)
Section Number
Without Dart Design - Green
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Reduce & Prevent Springback from Product Design Stage
DFE offers tools to generate & manipulate Diamond Shape Stiffener & Rib Shape Stiffener
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Generate “Diamond” Shape Stiffener - Examples
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Generate Diamond Shape Stiffener - Processing Path
Generate “Diamond” Shape Stiffener
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Generate “Diamond” Shape Stiffener
Diamond Parameter After base point is defined, the program will give a set of parameters.
H1 Height 1 of Diamond
H2 Height 2 of Diamond
W Diamond Width along center line of fillet.
R1 Radius1
R2 Radius2
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Class A Surface Defect Detection Processing
Using
Light Strip and
Stoning
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Move light strips to detect surface defects over the panel
Door Outer – Light Strip Visualization
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To simulate the stoning test for body outer panels in the shop
This function will identify the surface defect (dips, dimples, etc.) on the part surface
Door Panel Simulation Result after Springback
Stoning Test Simulation – Example
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Stoning Test Results from the Shop
Left hand side
Right hand side
Surfaces Defect Identified
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Stoning Test Simulation – Example
Result from Stoning function
Very good correlation with testing result
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Progressive Tooling Die Face Layout and
Multiple Stage Simulations
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Methodology – Product Design & Processing Data Received
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Methodology – Unfold the Part Geometry for Tooling Design
Product Design
Reverse Folding
Reverse Flanging
Reverse Bending
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Methodology – Create Tooling
Creating Tools
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Methodology – Layout the Tooling Stations
Tooling station layout using Tool Position function
Material translation consistent with station layout
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DYNAFORM’s Auto Setup – Single Setup & Execution A 10 - Station Progressive Tooling Simulation
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10 Stage Simulation – Movement with Tools
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10-Stage Simulation – Formability (FLD)
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Optimization – Sheet Metal Forming Applications
• 1D Applications – Drawbead Rates, Binder Force, Lubrication, Material and
Gage, etc..
• 2D Applications – Drawbead Segment, Binder Profiles, Addendum Profiles,
PO Line and etc.
• 3D Applications – Binder Surface, Addendum Surface
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Forming Based Optimization – Case Study
• Drawbeads are designed to restrict the blank from wrinkling & splitting in a forming process
• Adjusting Drawbeads layout of a large / complicated drawbead setup can be very challenging, very time consuming to achieve a formable panel/part, take weeks
• Efficiently utilize the optimization technology with modern computing power for Drawbead Forces optimization is practical to achieve a optimum configuration in a reasonable time frame, take days
Typical Die Face Layout Punch
Binder
19 Line Beads Die Face
Blank
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Typical Draw Beads – Parametrically Defined
Round Bead Square Bead
Male Bead & Female Bead Additional discussion
On Slide 70
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Optimization Based on (6) FLD Zones
Zone 1 ( Safe)
Zone2 (Marginal) Zone3 ( Split or Fail)
Zone 4 (Wrinkle Tendency)
Zone 5 (Wrinkle)
Zone 6 (Severe Wrinkle)
Define Constrain/Objective function as the ratio of elements in a particular Zone # / total elements
Forming Limited Diagram (FLD)
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Optimization Flow Chart
Optimization GUI
Red Cedar Sherpa
Run INCSolver
FORMABILITY
eta/Post Extraction Scripts
Update Response
Update Database with Best Formability
Performance
End
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GUI of Optimization Overview
Definition Forming Stages Design
Variables
Define Objectives and Constrains
Optimization Solver Status
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Case Study: Fender (NUMISHEET02), Stretch Forming
Punch Binder
15 Line Beads Die Face
Blank
INCSolver Draw Setup Parameters: Material: HSS_FENE Thickness: 0.7mm Binder Force: 1200000N Lower Binder Travel: 130mm Friction: 0.125 0.125 0.125 0.125 Adapt mesh level: 2 Initial element size: 16mm 4mm
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15 Line Beads were setup for optimization: The type of variable is continuous, values are changes from 5% to 80%. The base line of each variable is 60%.
Optimization Objective and Constraint all are “Crack/Split” and “Safe”. Number of Iteration are 185.
Case Study: Fender, Optimization Setup
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SHERPA returns the best/optimized parameters – 15 Line Bead Rates;
Case Study: Fender, Optimization Results
Bead ID Base Line Rate Optimized 1 60 5 2 60 70 3 60 5 4 60 15 5 60 25 6 60 5 7 60 75 8 60 5 9 60 5
10 60 5 11 60 15 12 60 5 13 60 80 14 60 5 15 60 70
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Case Study: Fender, FLD Plot, Before and After Optimization
Before Design OpDmizaDon
AHer the Design OpDmizaDon, based on FLD presentaDon, the Crack / Split area is significantly reduced.
AHer Design OpDmizaDon
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CASE Objective and constraint Iteration CPU
Calculate Time ( Hours)
Fender Crack, Safe 185 Inter(R) Core(TM) i7-2600 CPU
@3.40GHz 3.70 GHz 1 CPU/4 cores/8 threads
45
Case Study: Fender, Computing Resource
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Hot Forming Simulation Case Study -A-pillar
A-Pillar with a Local Reinforcement (Patch)
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Part information
patch
A pillar
Part Name Material Thickness
A-‐pillar 22MnB5_AusteniDzed_Thermo 1.6 mm
Patch 22MnB5_AusteniDzed_Thermo 1.95 mm
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Die Face Design
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Tooling Setup ( 3 piece die)
upper
binder
post
Binder travel 85 mm
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Blank Size
Patch Blank
A-‐Pillar Outer Blank
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Thickness
Wrinkles
Wrinkles
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Thickness
1.25 mm
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Thickness on Patch Part
2.28 mm
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Binder Close
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70 mm from home
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50 mm from home
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45 mm from home
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40 mm from home
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35 mm from home
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30 mm from home
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25 mm from home
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20 mm from home
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20 mm from home
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15 mm from home
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10 mm from home
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5 mm from home
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1 mm from home
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Home
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Material Inflow / Draw Inn
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Temperature in 0C
0C
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Temperature in 0C
0C
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Conclusion
• Thinning of 1.25 mm( 21.8%) in one spot(page 8)
• Wrinkles areas observed, one of wrinkle area is located on the trimline
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Conclusions and Further Developments
• Springback, Springback Compensation plus Springback Prevention Design
• Optimizations, 1D, 2D and 3D – “Black Box” setup enable average tooling users to adopt optimization approach for
forming applications – SMP & Multiple CPUs / Cores computing is needed for demanding optimization
calculations – Need to improve Overall Efficiency
• Hot Forming and Other Alternative Forming applications are ready for implementation
– Hot Stamping, Quenching and Die Structure Cooling
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Thanks for your Time and Attention
Q & A