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Satic Implicit Static Explicit Dynamic Explicit - PowerPoint PPT Presentation


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Possible simulation techniques in metal forming. Satic Implicit Static Explicit Dynamic Explicit. Smooth Particle Hydrodynamics Element Free Galerkin Method Moving Least Square Method Approximation Reproducing Kernel Particle Method. Modular Structure of Forming Processes.

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Presentation Transcript
slide1

Possible simulation techniques in metal forming

Satic Implicit

Static Explicit

Dynamic Explicit

SmoothParticle Hydrodynamics

Element Free Galerkin Method

Moving Least Square Method Approximation

Reproducing Kernel Particle Method

slide2

Modular Structure of Forming Processes

reference: K. Lange, Stuttgart

slide5

Topics

  • Why Forging Simulation?
slide6

Conventional Product Development

Customer

Specs

Prototype

Testing

Mass

Production

Design &

Tool Dev.

Pilot Stage

  • 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

Reduce ‘s, improve time to market !

slide7

simulation

Customer

Specs

Prototype

Testing

Prototype

Testing

Mass

Production

Mass

Production

Design &

Tool Dev.

Pilot Stage

Pilot Stage

  • Shorter Development Time:
  • less trial and error
  • less blocking of production line
  • optimized for available press
  • less visible defects
  • Less Fine Tuning:
  • improved quality
  • less invisible defects

Mass

Production

Pilot Stage

time to market

shorter time to market

Simulation-Aided Product Development

Be First to Market with Better and Cheaper Products !

slide8

simulation

Customer

Specs

Prototype

Testing

Mass

Production

Design &

Tool Dev.

Pilot Stage

  • Optimization during product life time:
  • extend die life
  • minimize material scrap
  • optimize process conditions
  • optimize press capacity utilization

Additional 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

Reduce Costs during Mass Production !

why simulation
Why Simulation
  • Reduce Time to Market
  • Reduce Cost of Tool Development
  • Predict Influence of Process Parameters
  • Reduce Productions Cost
  • Improve Product Quality
  • Better Understanding of Material Behavior
  • Reduce Material Waste
slide10

Manufacturing Results

  • Accurately predict the material flow
  • Determine degree of filling of the swage or die
  • Accurate assessment of net shape
  • Predict if laps or other defects exist
  • Determine the stresses, temperatures, and residual stresses in the work piece.
  • Determine optimal shape of preform
slide11

Material Behavior

  • Determine material properties such as grain size
  • Determine local hardness
  • Predict material damage
  • Predict phase changes and composition
  • Simulate the influence of material selection
slide12

Tool Results

  • Determine the forming loads
  • Determine the stresses in the tools
  • Evaluate tool wear or fatigue
  • Simulate the influence of lubrication
  • Optimize multi-tool process
slide13

Simulation allows you to capture behavior that can not be readily measured – providing deeper insight into your manufacturing processes

slide14

Damage Prediction - Chevroning

Multi-stage

Hydraulic Press with Annealing

Transfer Press

slide16

Kinematics

  • Placing the workpiece
  • Closing the tools
  • Forming process
  • Removal of the tools
  • Extraction of the workpiece
    • Including spring-back
  • Subsequent cool-down
slide17

Flexible Tool Definition

  • Rigid Tools
  • Deformable
  • Direct CAD NURB Description
slide18

Material Models

  • Power Laws
  • Johnson-Cook
  • Kumar
  • Grain Size Prediction
  • Phase Changes
  • Elastic Plastic
  • Rigid Plastic
  • Material Database
  • Isotropic hardening
  • Cowper-Symonds
slide19

Effects of Elasticity

  • Elasticity of Tools
  • Prestressed Dies
  • Residual Stresses
  • Behavior of part during ejection or removal
  • Determination of tolerances
slide20

Friction

  • Friction Influences:
    • load and energy requirements
    • metal flow
    • pressure distribution
    • die wear
  • Friction Models
    • Coulomb friction
    • plastic shear friction
    • combination
  • User-extendable Database
slide21

Visualization

  • Tracking of Material Particles
  • Flow Line Images
  • Time History of Tool Forces
  • Deformation of Workpiece
  • Contour Plots of all Quantities
slide22

Material Cost Savings

The cost of NOT doing it right the first time?