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

DYNA3DDYNA3D LSTC, USA/LSTC, USA/ explicit, dynamicexplicit, dynamic crash, bulk, sheet metalcrash, bulk, sheet metal

PAM-STAMPPAM-STAMP ESI, F/DESI, F/D explicit dynamicexplicit dynamic sheet metal formingsheet metal forming

OptrisOptris Dynamic Software, FDynamic Software, F explicit dynamicexplicit dynamic sheet metal formingsheet metal forming

MSCDYTRANMSCDYTRAN MacNeal-SchwendlerMacNeal-Schwendler explicit dynamicexplicit dynamic sheet metal formingsheet metal forming

ABAQUS-explicitABAQUS-explicit HKS, USAHKS, USA explicit dynamicexplicit dynamic crash, bulk, sheet metalcrash, bulk, sheet metal

AUTOFORMAUTOFORM AUTOFORM, CHAUTOFORM, CH Spec. formulation implicitSpec. formulation implicit sheet metal formingsheet metal forming

AutoforgeAutoforge MARC, USA/NL, DMARC, USA/NL, D elastic – viscoplasticelastic – viscoplastic bulk, forgingbulk, forging

DEFORMDEFORM BatelleBatelle, USA, D, USA, D rigid – viscoplasticrigid – viscoplastic bulk, forgingbulk, forging

FORGE 2/3FORGE 2/3 CEMEF, FCEMEF, F rigid – viscoplasticrigid – viscoplastic forgingforging

ICEM – STAMPICEM – STAMP Control Data, DControl Data, D one – step methodone – step method sheet metal formingsheet metal forming

ISO – PUNCHISO – PUNCH Sollac, FSollac, F one - step methodone - step method sheet metal formingsheet metal forming

AUTOFORM One – stepAUTOFORM One – step AUTOFORM, CHAUTOFORM, CH one – step methodone – step method sheet metal formingsheet metal forming

FASTFORMFASTFORM FTI, CanadaFTI, Canada one – step methodone – step method sheet metal formingsheet metal forming

SIMEX 2SIMEX 2 SimTech, FSimTech, F one – step methodone – step method sheet metal formingsheet metal forming

Commercially available FE programs for forming process simulation

TopicsTopicsTopicsTopics

•Why Forging Why Forging Simulation?Simulation?

ConventionalConventional Product Product DevelopmentDevelopment

Expensive Fixes:• visible defects• press capacity exceeded• underfilling (drop forging)• high localized die loads

More Expensive Fixes:• “invisible” defects• unacceptable tolerances

Most Expensive Fixes:• short die life• unstable process conditions

CustomerSpecs

Design &Tool Dev.

PrototypeTesting

Pilot Stage

MassProduction

Reduce ‘s, improve time to market !

Simulation-AidedSimulation-Aided Product Product DevelopmentDevelopment

simulation

CustomerSpecs

Design &Tool Dev.

PrototypeTesting

Pilot Stage

MassProduction

time to market

PrototypeTesting

Pilot Stage

MassProduction

shorter time to market

Pilot Stage

MassProduction

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

Damage Prediction - Damage Prediction - ChevroningChevroning

Multi-stage

Hydraulic Press with Annealing

Transfer Press

Possible forming of laps and its Possible forming of laps and its prediction through simulation prediction through simulation techniquetechnique

KinematicsKinematics

• Placing the workpiecePlacing the workpiece

• Closing the toolsClosing the tools

• Forming processForming process

• Removal of the toolsRemoval of the tools

• Extraction of the workpiece Extraction of the workpiece – Including spring-backIncluding spring-back

• Subsequent cool-downSubsequent cool-down

Flexible Tool DefinitionFlexible Tool Definition

• Rigid ToolsRigid Tools

• DeformableDeformable

• Direct CAD NURB DescriptionDirect CAD NURB Description

Material ModelsMaterial Models

• Elastic Plastic Elastic Plastic

• Rigid PlasticRigid Plastic

• Material DatabaseMaterial Database

• Isotropic Isotropic hardeninghardening

• Cowper-SymondsCowper-Symonds

• Power LawsPower Laws

• Johnson-CookJohnson-Cook

• KumarKumar

• Grain Size Grain Size PredictionPrediction

• Phase ChangesPhase Changes

Effects of ElasticityEffects of Elasticity

• Elasticity of ToolsElasticity of Tools

• Prestressed DiesPrestressed Dies

• Residual StressesResidual Stresses

• Behavior of part during ejection or Behavior of part during ejection or removalremoval

• Determination of tolerancesDetermination of tolerances

FrictionFrictionFrictionFriction• Friction Influences:Friction Influences:

– load and energy requirementsload and energy requirements– metal flowmetal flow– pressure distributionpressure distribution– die weardie wear

• Friction ModelsFriction Models– Coulomb frictionCoulomb friction– plastic shear frictionplastic shear friction– combinationcombination

• User-extendable DatabaseUser-extendable Database

VisualizationVisualization

• Tracking of Material ParticlesTracking of Material Particles

• Flow Line ImagesFlow Line Images

• Time History of Tool Forces Time History of Tool Forces

• Deformation of WorkpieceDeformation of Workpiece

• Contour Plots of all QuantitiesContour Plots of all Quantities

Material Cost Material Cost SavingsSavingsMaterial Cost Material Cost SavingsSavings

The cost of NOT doing it right the first time?

Thank You!Thank You!Thank You!Thank You!