Process simulation in stamping _ recent applications for product and process design

摘要

Process simulation for product and process designis currently being practiced in industry. However. a number ofinput variables have a significant effect on the accuracy andreliability of computer predictions. A study was conducted toevaluate the capability of FE-simulations for predicting pancharacteristics and process conditions in forming complex-shaped,industrial parts.In industrial applications, there are two objectives for conductingFE-simulations of the stamping process; (1) to optimize theproduct design by analyzing formability at the product design stageand (2) to reduce the tryout time and cost in process design bypredicting the deformation process in advance during the diedesign stage. For each of these objectives, two kinds of FE-simulations are applied. Pam-Stamp, an incremental dynamic-explicit FEM code released by Engineering Systems Int'l. matchesthe second objective well because it can deal with most of thepractical stamping parameters. FAST_FORM3D. a one-step FEMcode released by Forming Technologies. Matches the firstobjective because it only requires the pan geometry and not thecomplex process information.In a previous study. these two FE codes were applied to complex-shaped parts used in manufacturing automobiles and constructionmachinery. Their capabilities in predicting formability issues instamping were evaluated. This paper reviews the results of thisstudy and summarizes the recommended procedures for obtainingaccurate and reliable results from FE simulations.In_ another study. the effect of controlling the blank holderforce (BHF) during the deep drawing of hemispherical, dome-bottomed cups was investigated. The standard automotivealuminum-killed. drawing-quality (AKDQ) steel was used as wellas high performance materials such as high strength steel. bakehard steel. and aluminum 61 I I. It was determined that varying theBHF as a function of stroke improved the strain distributions inthe domed cups.