The best way to answer this question is via the Forming Limit Diagram (FLD). The colors and predictions of splits/compression, etc., are all based on the the FLD.
It was established a few decades ago that metal forming limits can be predicted by using the FLD and there are TWO key parameters that set the position of the limit curve. One of these is MATERIAL THICKNESS.
As material thickness INCREASES, the limit curves moves UP the Y axis and therefore, the limits of the material are greater. That is, a thicker material will accept (tolerate) more strain before failure occurs. This has been proven many times in simulation and the real world.
To remove any risk of splits, one possibility is to increase the material thickness. HOWEVER, this is usually undesirable because this also increases material costs which can often be as much as 70% of a part's cost! Another point to be aware of, is that the YELLOW (risk of splits) is a safety margin before splits are definitely predicted.
It is possible to REMOVE this criterion in which case, the yellow areas would simply turn green (SAFE) but this leaves absolutely no room for production variation.
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.
It was established a few decades ago that metal forming limits can be predicted by using the FLD and there are TWO key parameters that set the position of the limit curve. One of these is MATERIAL THICKNESS.
As material thickness INCREASES, the limit curves moves UP the Y axis and therefore, the limits of the material are greater. That is, a thicker material will accept (tolerate) more strain before failure occurs. This has been proven many times in simulation and the real world.
To remove any risk of splits, one possibility is to increase the material thickness. HOWEVER, this is usually undesirable because this also increases material costs which can often be as much as 70% of a part's cost! Another point to be aware of, is that the YELLOW (risk of splits) is a safety margin before splits are definitely predicted.
It is possible to REMOVE this criterion in which case, the yellow areas would simply turn green (SAFE) but this leaves absolutely no room for production variation.
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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