automotive sheet metal part simulation and tool surface derivation
TRANSCRIPT
2011 HyperWorks Technology Conference
„Automotive Sheet Metal Part Simulation and Tool Surface Derivation“
09.11.2011
Stefan Heinemann
08.07.2011
Stefan Heinemann Seite 2
Agenda
1.1.1.1. Abstract and Abstract and Abstract and Abstract and IntroductionIntroductionIntroductionIntroduction
2. Thesis
3. Analysis
4. Discussion
5. Conclusion
6. Acknowledgements, References
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1. Abstract + Introduction
VW VW VW VW ---- ProductProductProductProduct DevelopmentDevelopmentDevelopmentDevelopment ProcessProcessProcessProcess (48Month)(48Month)(48Month)(48Month)„Idea“„Car on
the Road“
Press Die Development
and Manufacture
(~24Month)
R&D,
SE
Launch &
Production
… …
Decreasing Tendency!!!
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1. Abstract + Introduction
Press Die Development
and Manufacture
(~24Month)
Simulation & EngineeringSimulation & EngineeringSimulation & EngineeringSimulation & Engineering MachiningMachiningMachiningMachining, , , , AssemblyAssemblyAssemblyAssembly and and and and TryoutTryoutTryoutTryout
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1. Abstract + Introduction
Strong necessity to reduce the overall time to market, including press- die development and manufacturing time
Due to:
- strong international competition
- new models, facelifts with shorter lifecycles
- reduction of investment- budgets before market launch
�Main Main Main Main focusfocusfocusfocus of of of of thisthisthisthis presentationpresentationpresentationpresentation
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Agenda
1. Abstract and Introduction
2.2.2.2. ThesisThesisThesisThesis
3. Analysis
4. Discussion
5. Conclusion
6. Acknowledgements, References
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2. Thesis
TheTheTheThe applicationapplicationapplicationapplication of CAE of CAE of CAE of CAE toolstoolstoolstools supportssupportssupportssupports and and and and acceleratesacceleratesacceleratesaccelerates thethethethe Press Die Press Die Press Die Press Die
ManufacturingManufacturingManufacturingManufacturing ProcessProcessProcessProcess in in in in variousvariousvariousvarious processprocessprocessprocess milestonesmilestonesmilestonesmilestones, , , , e.ge.ge.ge.g.:.:.:.:
FeasibilityFeasibilityFeasibilityFeasibility:::: SE between R&D and Manufacture, to proof or to
enable physical part producability, based on: Part
Feasibility, Manufacturability, Process Capability [see Banabic]
OptimizationOptimizationOptimizationOptimization:::: Supports SE and Die Enginneering to improve part
quality and to reduce manufacturing costs [see Hillmann, Kubli]
Die Design:Die Design:Die Design:Die Design: Die- form- derivation based on the process variables
to support further design specification (cams, standards)
MoreMoreMoreMore detailsdetailsdetailsdetails in in in in thethethethe Analysis Analysis Analysis Analysis sectionsectionsectionsection…………
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Agenda
1. Abstract and Introduction
2. Thesis
3.3.3.3. AnalysisAnalysisAnalysisAnalysis
4. Discussion
5. Conclusion
6. Acknowledgements, References
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3. Analysis
1. Part 1. Part 1. Part 1. Part FeasibilityFeasibilityFeasibilityFeasibility ((((basedbasedbasedbased on on on on partpartpartpart geometrygeometrygeometrygeometry and material)and material)and material)and material)
1) One One One One StepStepStepStep AnalysisAnalysisAnalysisAnalysis: to proof physical manufacturability of a certain final part
data status (FLD based)
2) IncrementalIncrementalIncrementalIncremental Simulation:Simulation:Simulation:Simulation: to proof process parameters during the forming
process (thinning values, strains…) to approve/ reject Feasibility- status
� duration: ~2- 3month for „common“ parts (iterative process)
� Additional confirmation by hardware prototype tools (invest++)
Part Model e.g.
P- Release*
?
* Planning Release
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3. Analysis
2. 2. 2. 2. ManufacturabilityManufacturabilityManufacturabilityManufacturability ((((ProcessProcessProcessProcess Validation) Validation) Validation) Validation)
Part Geometry Step 1
(Drawing)Step 2
(Cutting)Step 3
(Reforming)Step 4
(Flanging)
„Example, Process“
…-To validate each single step, e.g.
- Undercuts
- Cam Directions
- Surface Defects, …
� Multistage Forming Simulation (Software)
� Tryout hardware tools (invest++)
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3. Analysis
3. 3. 3. 3. ProcessProcessProcessProcess CapabilityCapabilityCapabilityCapability ((((ProductionProductionProductionProduction RobustnessRobustnessRobustnessRobustness) ) ) )
Repeatability:
- during factory conditions/ variables (tolerances, wear,…)
- corresp. process parameters (# press-strokes, tooling influences,…)
� Simulation only partly possible (stochastic influences)
� real part simulation (e.g. Tooling, Tryout)
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3. Analysis
OptimizationOptimizationOptimizationOptimization ((((herehereherehere FLD FLD FLD FLD basedbasedbasedbased) ) ) )
SAFESAFE
FAIL (Cracks)FAIL
TENSION- TENSIONTENSION-
COMPRESSION
CRITICAL STRAIN
Minor Engineering Strain %
Ma
jor
En
gin
ee
rin
g S
tra
in%
Wrinkles
FLC
FormingFormingFormingForming Limit DiagramLimit DiagramLimit DiagramLimit Diagram
(Material specific)
- to determine fail/safe criteria for
each Finite Element
[see Banabic; Behrens]
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3. Analysis
OptimizationOptimizationOptimizationOptimization ((((herehereherehere FLD FLD FLD FLD basedbasedbasedbased) ) ) )
QualityQualityQualityQuality FunctionFunctionFunctionFunction to to to to minimizeminimizeminimizeminimize
Cracks-, wrinkles failures
- Minimizing distance to QF for
each Finite Element
Design VariablesDesign VariablesDesign VariablesDesign Variables (Process, Shape)
e.g. Radii, Opening Angles, Binder
Forces
[see Altair]
Minor Engineering Strain %
Ma
jor
En
gin
ee
rin
g S
tra
in%
Failure Line
Quality
FunctionCompression
Line
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3. Analysis
Die Design (Die Design (Die Design (Die Design (e.ge.ge.ge.g. Draw Die). Draw Die). Draw Die). Draw Die)
TextTextTextText
TextTextTextText
TextTextTextText
Text
Text
TextTextTextText
TextTextTextTextTool
Surfaces
Addendum
+ Binder
Part Design
Press Die Design
+ Machining Data
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Agenda
1. Abstract and Introduction
2. Thesis
3. Analysis
4.4.4.4. DiscussionDiscussionDiscussionDiscussion
5. Conclusion
6. Acknowledgements, References
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4. Discussions
Application of Simulation and CAE support extends Engineering
phase, but shortens and impoves quality of Manufacturing!
- Engineering Phase: mostly Software Simulation (rel. low invest)
- Manufacturing Phase: Hardware Simulation with Software support
(very high invest)
� Savings (financial + time) and Results in Manufacturing
compensate Simulation effort by far
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Agenda
1. Abstract and Introduction
2. Thesis
3. Analysis
4. Discussion
5.5.5.5. ConclusionConclusionConclusionConclusion
6. Acknowledgements, References
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5. Conclusions
CAE CAE CAE CAE involvementinvolvementinvolvementinvolvement unamenableunamenableunamenableunamenable in Press Die in Press Die in Press Die in Press Die ManufacturingManufacturingManufacturingManufacturing!!!!
- Reliable Forming Simulation and Process Confirmation
- Predictions for Part Quality
BenefitsBenefitsBenefitsBenefits forforforfor ManufacturingManufacturingManufacturingManufacturing ProcessProcessProcessProcess
- Reduction of Tryout Time
- Improvement of Part Quality for a given part design
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Agenda
1. Abstract and Introduction
2. Thesis
3. Analysis
4. Discussion
5. Conclusion
6.6.6.6. AcknowledgementsAcknowledgementsAcknowledgementsAcknowledgements, , , , ReferencesReferencesReferencesReferences
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6. Acknowledgements
Thanks to:
ALTAIR Germany for Software Support
ALTAIR Michigan for Problem Support
Volkswagen AG (Press- Die Devision)
TU- Braunschweig (Institut für Konstruktionstechnik)
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6. References
[[[[BanabicBanabicBanabicBanabic]]]]
D. Banabic: „Sheet Metal Forming Processes“ Springer 2010
[Hillmann, [Hillmann, [Hillmann, [Hillmann, KubliKubliKubliKubli]]]]
M. Hillmann, W. Kubli: „Finding the best way to form automotive sheet metal
parts – using parametric die face design and optimization“ SAE Paper: 2000
[Behrens][Behrens][Behrens][Behrens]
B.-A. Behrens, E. Doege: „ Handbuch Umformtechnik“ Springer 2010
[[[[AltairAltairAltairAltair]]]]
Hyperform Tutorial and User‘s Guide, Altair Engineering 2011
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Q&A, Thank you!