We would like to explore the capabilities of forming simulation, as well as provide some descriptions of how the technology works. So here is a quick summary of a few typical applications of metal forming simulation technology. Being aware that metal forming simulation is actually a specific application of the Finite Element Method (FEM also known as FEA) may assist your understanding.
Material yield (utilization) calculations and blank shape estimates.
Using a 3D CAD model of the final part, the data is meshed automatically and then “unrolled” or developed to a flat blank shape. From here, blank nesting and rectangular, trapezoid or any other shape fitting can be applied. The final data produced is a 2D CAD line that can then be used to calculate material utilization across any blank nesting or shape configurations.
Tip angles (or part tipping) and undercut checks.
Using the 3D CAD of the final part shape, the data is automatically tipped into the most suitable pressing angle with the intent to ensure that no elements in the mesh “undercut” the vertical motion of a press machine. This step provides a very quick indication of the possibility of forming the desired part shape in one process or whether there is a need to do it in two or three or more processes. If there are undercutting areas, they are highlighted and decision can be made as to whether the part shape can be changed (to avoid the undercutting) or whether an additional forming process is needed. This step sets the press tip angles and positions the 3D CAD model into the pressing coordinate system, ready for further die face designing.
Forming simulation (or drawing simulation).
At first, die face data has to be created. Using the final part shape that has been tipped into the pressing direction, die face surfaces are created. For example, in a simple crash form, the boundaries of the part simply need to be extended, but in a draw process, addendum and binder surfaces need to be created. With this, the earlier developed blank shape (square, pre-trimmed or otherwise) is used with the newly created die face surfaces to run the simulation.
About StampingSimulation.com
StampingSimulation.com is a world wide team of specialist forming simulation and sheet metal forming engineers. With resources across three continents (North America, Europe and Australasia) we are uniquely placed to offer fast turn around times on all structural simulation, hydro forming simulations, ANSYS simulations and sheet metal forming simulations.
About AutoForm
AutoForm offers software solutions for the die-making and sheet metal forming industries, and is recognized by the Top 20 automobile producers and their customers, as the number one provider of software for product formability, die face design and virtual tryouts to the global automotive industry. The use of AutoForm software improves
reliability in planning, reduces the number of die tryouts and tryout time, and results in higher quality part and tool designs that can be produced with maximum confidence. In addition, press downtime and reject rates in production are substantially reduced.
Material yield (utilization) calculations and blank shape estimates.
Using a 3D CAD model of the final part, the data is meshed automatically and then “unrolled” or developed to a flat blank shape. From here, blank nesting and rectangular, trapezoid or any other shape fitting can be applied. The final data produced is a 2D CAD line that can then be used to calculate material utilization across any blank nesting or shape configurations.
Tip angles (or part tipping) and undercut checks.
Using the 3D CAD of the final part shape, the data is automatically tipped into the most suitable pressing angle with the intent to ensure that no elements in the mesh “undercut” the vertical motion of a press machine. This step provides a very quick indication of the possibility of forming the desired part shape in one process or whether there is a need to do it in two or three or more processes. If there are undercutting areas, they are highlighted and decision can be made as to whether the part shape can be changed (to avoid the undercutting) or whether an additional forming process is needed. This step sets the press tip angles and positions the 3D CAD model into the pressing coordinate system, ready for further die face designing.
Forming simulation (or drawing simulation).
At first, die face data has to be created. Using the final part shape that has been tipped into the pressing direction, die face surfaces are created. For example, in a simple crash form, the boundaries of the part simply need to be extended, but in a draw process, addendum and binder surfaces need to be created. With this, the earlier developed blank shape (square, pre-trimmed or otherwise) is used with the newly created die face surfaces to run the simulation.
About StampingSimulation.com
StampingSimulation.com is a world wide team of specialist forming simulation and sheet metal forming engineers. With resources across three continents (North America, Europe and Australasia) we are uniquely placed to offer fast turn around times on all structural simulation, hydro forming simulations, ANSYS simulations and sheet metal forming simulations.
About AutoForm
AutoForm offers software solutions for the die-making and sheet metal forming industries, and is recognized by the Top 20 automobile producers and their customers, as the number one provider of software for product formability, die face design and virtual tryouts to the global automotive industry. The use of AutoForm software improves
reliability in planning, reduces the number of die tryouts and tryout time, and results in higher quality part and tool designs that can be produced with maximum confidence. In addition, press downtime and reject rates in production are substantially reduced.
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