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INTRODUCTION
Sheet metal forming is one deformation process whichtransforms a metal blank into a component
Wrinkling and tearing are the most prevalent materialinstabilities that occur in sheet metals formed by stampingand deep drawing processes
Finite Element Analysis (FEA) is a numerical simulation
that allows us to evaluate product manufacturability andpredict the defects at early stages of the design process
OBJECTIVES
To identify part defect of an automotive stamped part
To simulate the selected part using DYNAFORM softwareto analyze its formability
To optimize the part process to reduce cost and save time
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PROBLEM STATEMENT
Many company still using trial and error method to obtainthe most acceptable process to produce their partsResulting time consuming, high cost and error to determinethe accuracy of actual designStamped part have a crack and tearing defectsRecommended step for the stamped part
SCOPE OF PROJECT
Automotive stamped part collected from Autokeen Sdn.Bhd.
Actual design will go through the numerical simulation byusing DYNAFORM software to analyze the formability of the partThe data will be collected and recommendation is made tooptimize the part process
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SIGNIFICANCE OF PROJECT
Impart the knowledge and understanding on the concepts of stamping die
eta/DYNAFORM software can be used as simulation toolfor the numerical analysis and can reduced try and errormethod
The drawing steps is reduced to get lower cost and higherproduction efficiency
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SpecificationPart name BRACKET ASSEMBLY SPRING UPPER
Drawing no. MR491947
Process(i) Semi progressive, 250 tonne
(ii) Flange, pierce, 110 tonne
Material SPCC, thickness = 2.3mm
Dies Material Surface Treatment
Upper punch SKD11 Full hardened
Lower punch SKD11 Full hardened
Machine name Komatsu 250 tonne
PART IDENTIFICATION
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Convert the CATIA drawing to .iges file
in the CATIA software
Import the .iges file into theeta/DYNAFORM software
Generate inner and outer surface of thepart to set the punch and die.
Generate blank and blank holder (orbinder) in 1 st Draw
Generate upper pad and lower pad (orbinder) in 2 nd, 3 rd and 4 th draw
Run the LS-Dyna Analysis in theAUTOSETUP menu
Open the analysis result by using theETA/Postprocessor
STEP TO DO THE ANALYSIS BY USING LS-DYNA
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Actual Simulation
2nd draw output
Draw stage 1 2 3
% from failure zone 64.15 - -
Minimum Thickness (mm) 2.053 0.596 0.089
Maximum Major Strain 0.231 1.279 3.271
SUMMARY RESULTS FOR 3 STAGES OF DRAW
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Actual Simulation
4 th draw output
Draw stage 1 2 3 4
% From Failure Zone 40.82 40.00 39.13 9.43
Minimum Thickness
(mm)1.773 1.823 1.564 1.384
Maximum Major Strain 0.305 0.450 0.620 0.807
SUMMARY RESULTS FOR 4 STAGES OF DRAW
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DISCUSSION OF PART SIMULATION
The FLD shows the critical combinations of major strainand minor strain in the sheet surface
Safety curve verify whether a stamping will be crack free
FLC limit of the drawn part to be crack
FLC
SafetyCurve
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OPTIMIZATION PROCESS FLOW
Identify required steps
Estimate blank diameter
Determine the number of draws
Optimal ratio of reduction
Design in CATIA software
Simulate using DYNAFORM software
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DISCUSSION OF PART PROCESS OPTIMIZATION
Through the analysis comparison between optimizationprocess and four stages draw process, the optimizationprocess is more preferable process to be implemented
Optimization Process Four Stages Draw Process
% From Failure Zone 48.44 9.43
Thickness Distribution 1.837 1.384
Major Strain 0.576 0.807
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Optimization Process 4 stages draw process
Forming LimitDiagram
ThicknessDistribution
Major Strain
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CONCLUSION
The analysis proved that the optimization process is morepreferable method as compare to the previous four stagesprocess
The more percentage from the failure zone means the parthas a better quality
25 percent of the die material, scrap and time can be savedby eliminating one stage of the draw process
OptimizationProcess
Four Stages DrawProcess
Total cost(per unit)
RM 3.66 RM 3.89
Timeconsumed(per unit)
24 sec 28 sec