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.
Splitting, thinning and wrinkling checks.
It goes without saying that the primary purpose of the forming simulation step is to check how the material behaves prior to machining of any tool steel.
The results produced in the forming simulation step illustrate very clearly the calculated areas of material yielding (splitting), amounts of necking (thinning or changes in thickness) and areas of material compression (wrinkles and folds). The Forming Limit Diagram (FLD) is key to analyzing this data as it plots each element’s strain (in major and minor axis) on a graph and compares it to the material’s limits to determine if any of these defects will be present. With this information in hand, countermeasures and adjustments are made to the die face design and then the forming
simulation is re-run, until each defect is removed or an acceptable result is achieved.
Die face data export.
After all the problems have been ironed out of the draw process and an acceptable “draw panel” has been produced in the virtual environment, the die face data that was used in the simulation can be exported as CAD (IGES, STL or any other format) for use when designing a complete tool and creating NC cutter paths. Basically, the die face data can be used in any other CAD/CAM package for use in an actual tool build.
Blank shape development.
There are many cases where it is not possible to simply blank the material to the shape estimated in the first step (blank shape estimate), form it and end up with a perfect result. If the part needs to be drawn then wiped down, for example, then some trimming occurs after drawing and needs to be developed so that after the wipe-down, the trim length is correct. With the sheet metal forming simulation software, this can all be done in a virtual environment. After the draw simulation step is complete, the “virtual draw panel” can be virtually “laser trimmed”, then wiped or flanged down. The
virtual laser trim shape can then be adjusted until the final trim line is developed to the correct shape. This means when the time comes to develop an actual trim die, a very accurate starting point is available, which rarely needs further adjustment, meaning the time and cost to build a real trim die, is drastically reduced.
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.
Splitting, thinning and wrinkling checks.
It goes without saying that the primary purpose of the forming simulation step is to check how the material behaves prior to machining of any tool steel.
The results produced in the forming simulation step illustrate very clearly the calculated areas of material yielding (splitting), amounts of necking (thinning or changes in thickness) and areas of material compression (wrinkles and folds). The Forming Limit Diagram (FLD) is key to analyzing this data as it plots each element’s strain (in major and minor axis) on a graph and compares it to the material’s limits to determine if any of these defects will be present. With this information in hand, countermeasures and adjustments are made to the die face design and then the forming
simulation is re-run, until each defect is removed or an acceptable result is achieved.
Die face data export.
After all the problems have been ironed out of the draw process and an acceptable “draw panel” has been produced in the virtual environment, the die face data that was used in the simulation can be exported as CAD (IGES, STL or any other format) for use when designing a complete tool and creating NC cutter paths. Basically, the die face data can be used in any other CAD/CAM package for use in an actual tool build.
Blank shape development.
There are many cases where it is not possible to simply blank the material to the shape estimated in the first step (blank shape estimate), form it and end up with a perfect result. If the part needs to be drawn then wiped down, for example, then some trimming occurs after drawing and needs to be developed so that after the wipe-down, the trim length is correct. With the sheet metal forming simulation software, this can all be done in a virtual environment. After the draw simulation step is complete, the “virtual draw panel” can be virtually “laser trimmed”, then wiped or flanged down. The
virtual laser trim shape can then be adjusted until the final trim line is developed to the correct shape. This means when the time comes to develop an actual trim die, a very accurate starting point is available, which rarely needs further adjustment, meaning the time and cost to build a real trim die, is drastically reduced.
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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