Consideration of uncertainties in forming simulation using HyperWorks
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Transcript of Consideration of uncertainties in forming simulation using HyperWorks
WWW.DTE-ONLINE.DE p.1
WWW.DTE-ONLINE.DE DTE
2013 European Altair Technology Conference
Consideration of uncertainties in forming simulation using
HyperWorks
Markus Reinert, DTE-Verfahrenstechnik
ENGINEERING SIMULATION
METHOD PLANNING DESIGN
KINEMATICS
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1. Introduction
2. Problem Definition
3. Discussion
4. Conclusion
5. Acknowledgements
6. References
Agenda
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1. Introduction
•DTE was founded in 2000
•24 employees in two locations Olpe and
Hamburg in Germany
•Complete service in the field of sheet metal
forming tools, mainly automotive
•Only software not hardware:
• Engineering
simulation; process planning;
feasibility studies; kinematical studies
• Tool designing
transfer tools; progressive tools
DTE Werkzeug and Verfahrenstechnik GmbH&Co. KG
Design Tool Engineering
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Manufacturing Process
1. Introduction
(Drawing) (Cutting)
(Cutting)
(Calibrating) (Punching)
Drawing and Springback Simulation with help of
•How to get a ready automotive sheet metal part out of a flat coil
•Create a Manufacturing Process with the help of CAD
•Simulation (FEM) is a helpful tool to ensure the feasibility of your Process
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1. Introduction Drawing Simulation (FEM)
Die geometries out of CAD
Preprocessing of the Simulation with HyperForm
Simulation with Radioss-Solver
Forming Parameters
•Sheet material data
•Friction
•Forces
•Velocities
•Drawing Clearance
•Etc.
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Drawing Simulation in engineering phase
Put results and information out of
the simulation into the Processplan
Put changed Forming-Geometries
and -Paramters into the simulation Springback
FLD
Thinning
1. Introduction
Postprocessing of the Simulation with HyperView:
Change Geometries in CAD:
•Drawing radius
•Die design
•Blank geometries
•Whole process
Change Forming Parameters in
Preprocessing :
•Forces
•Meshing Parameters
•Draw beads
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2. Problem Definition
Lightweight with high strength steels and aluminum
In the automotive industry, the lightweight is
an increasingly important issue. This leads
to the increased use of high strength steels
and aluminum. These materials decrease
the process capability of forming of many
automotive components than conventional
materials. It becomes more difficult to
predict the feasibility of CAE methods.
The feasibility region is getting smaller
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2. Problem Definition Simulation (CAE) is a Model of reality
There are many influential parameters
material quality
•Material data and flow curve (tensile
strength, yield strength, modulus of
elasticity, …)
•Anisotropy (rollingdirection, r-values)
•Thickness
•Tribology (surface of the sheet)
•Blank geometry
•Trim lines hardening
•etc.
Influenz on feasibility
Influenz on springback
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2. Problem Definition Simulation (CAE) is a Model of reality
There are many influential parameters
physical parameters
•Friction (die, binder)
•Binder force
•Forming geometries
(Drawing radius, clearance, …)
•Press parameters
(drawing velocity, pressing force during time,
tilting and deflection of press ram)
•Temperature
•Lubrication
•Drawbeads
•etc.
Influenz on feasibility
Influenz on springback
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More Problems
2. Problem Definition
Material change
• From Plate-Material to Coil-Material
• From one Material batch to another batch
Press change
• From Tryout Press to Serial Press
• From Serial Press to Replacement Press
Trim lines hardening on aluminum
• After cutting process there is a second
forming process
•Crack failure on bending trim line
Fluctuation on material quality
Fluctuation on physical parameters
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2. Problem Definition Simulation (FEM) is a model of reality
Reality Simulation FEM
Problem
•Simulation is OK
•First tryout is OK
•After changing the coil in real process there
are cracks!
•Why there are cracks? How we will be able
to make the process safety?
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How to deal with the uncertainties
Look critically on your Simulation Results
• are the results plausible
• compare your results with reality (ex post analysis)
Look at other results than Thinning and FLD
• plastic strain
• look at results over forming time
Integrate other Failure Model into Simulation
• Johnson Cook Failure
Sensitivity Analysis
• Study of the fluctuation of Forming Parameters using HyperStudy,
Design of Experiments (DoE)
3. Discussion
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3. Discussion
Other results (Plastic Strain along thickness)
Detect significant areas:
•It mustn't means there is a Crack or Failure
•Have a look at detected Elements at the rest
of Simulation-Analysis
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3. Discussion
Results over forming time (FLD)
At the end of
Simulation:
•Tensile
At the beginning of
Simulation:
•Compression
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Failure Model Johnson Cook
3. Discussion
Crack like reality
No cracks in reality
(>> use this Failure
Model carefully!)
How to determine D1, D2, D3 Parameters
(Excel List by Altair):
•Method of least squares to fit the rupture strain given by
function to experimental data (tension, compression, shear)
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HyperStudy; Design of Experiments (DoE)
3. Discussion
Fluctuating Parameter
(Design variables):
• Blank Thickness: ±10%
• Flow Curve: ±10%
• Binder Force: ±30%
• Die/Binder Friction: ±50%
HyperStudy at the end of Engineering and Simulation Process!
Detect critical nodes out of HyperView
(Responses):
• Response 1-5: max. plastic Strain or five nodes
• Response 6-10: min. thickness for same five nodes
Full Factorial DoE class:
• Each min. and max. Design variable with each other
>> 32 runs
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4. Conclusion
•Safety and robust manufacturing processes
•Reduction of Tryout Time and Tryout Problems
•Less waste in manufacturing processes
•Better Part Quality
•Less Costs in later product life cycle
Simulation by using HyperWorks and spend more time, knowhow and money in CAE brings benefits
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Thanks to ALTAIR Germany for Software and Problem Support
I especially thank Mr. Trickov for his personal
commitment
5. Acknowledgements
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ALTAIR, ”Reference Guide”, Altair 2012 V. Trikov, “Johnson Cook Failure”, Altair 2012
C. Held, R. Schleich, M. Sindel, M. Liewald, “Untersuchungen zum
Einfluss der Verfestigung von schergeschnittenen Kanten auf
folgende Umformprozesse,“ UTFscience 2/2009
6. References
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Thank You for Your attention!
Q & A