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Sheet Metal Forming

This document summarizes a student project involving numerical modeling and simulation to design sheet metal dies. It outlines the objective to apply simulation to process planning and die design. It then details the project phases including modeling a fuel tank protector part out of steel sheet metal 0.5mm thick. The modeling involves one-step analysis to identify formability issues, incremental analysis of the full forming process, concept development in CAD software, and modification of process parameters like friction and blank holder force in the simulation software. The document concludes by covering areas like die press calculations, CAD modeling, material optimization, and manufacturing of a scaled die prototype.

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592 views26 pages

Sheet Metal Forming

This document summarizes a student project involving numerical modeling and simulation to design sheet metal dies. It outlines the objective to apply simulation to process planning and die design. It then details the project phases including modeling a fuel tank protector part out of steel sheet metal 0.5mm thick. The modeling involves one-step analysis to identify formability issues, incremental analysis of the full forming process, concept development in CAD software, and modification of process parameters like friction and blank holder force in the simulation software. The document concludes by covering areas like die press calculations, CAD modeling, material optimization, and manufacturing of a scaled die prototype.

Uploaded by

syedamiriqbal
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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PROJECT GROUP #12 BATCH 2006-07

KASHIF ASHHAR ARSALAN ZAHEER M. FAYZAN SYED WAQAS ALI (031) (032) (059) (060)

PROJECT GROUP #12

OBJECTIVE
APPLICATION OF NUMERICAL MODELING AND SIMULATION IN DESIGNING OF SHEET METAL DIES

PROJECT GROUP #12

INTRODUCTION

Flow chart of process planning and die design in traditional CAD environment

Workflow in simulation based process planning and die design

PROJECT GROUP #12

PART
MATERIAL
SACE 120 CR-DDQ-AL (JISG3314) (ASTM A 463)

Protector, Fuel tank (Corolla -242L)

THICKNESS
0.5 mm

PROJECT GROUP #12

PHASE III
MODELING & SIMULATION
One step Analysis
To conclude simply whether a product as designed is formable with ease, & if not, to identify areas on the geometry that lead to formability issues

Starting Final product geometry only with: Sheet Thickness Material Specifications Setting Parameters Die Tip Lubrication Edge Restraint Conditions
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ONE STEP ANALYSIS RESULT(Geometry 1)

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Forming Limit Diagrams (Geometry 1)

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PROJECT GROUP #12

Forming Limit Diagrams (Geometry 2)

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INCREMENTAL ANALYSIS
A Full process model that simulates the forming stages as accurately as possible in logical order from blank holder closing to final flanging. With Capabilities to Analyze: Initial Deflection of Sheet due to gravity Blank holder Closing First Draws and Restrikes Cutting Operations Sheet Repositioning Flanging and Springback Hydro-Mechanical processes for Sheets and Tubes

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PROJECT GROUP #12

FIRST CONCEPT

CAD Surface geometry Of Fuel tank protector

Boundary Fill(brown),Binder(reddish brown) and Addendum ( green) created with Autoform Die Designer

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PRESS TONNAGE
CALCULATIONS:

PUNCH :
DIE

From graph: Punch force = 300kN By rule of thumb: (300kN)(2.5) = 750kN = 75tonn(approx) BLANK HOLDER: From graph: blank holding force = 120kN By rule of thumb: (120kN)(2.5) = 300kN = 30tonn(approx) PRESS TONNAGE; Press tonnage = punch force + blank holding force = 75tonn + 30tonn = 105tonn
PUNCH BLANK HOLDER

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INCREMENTAL ANALYSIS

SECOND CONCEPT

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Location of Wrinkles
Planar/Flat areas Curved areas Areas under binder

Threshold value
0.001 0.02 0.05

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PROJECT GROUP #12

FIRST MODIFICATION IN PROCESS PARAMETERS


Modify Coefficient of friction from 0.15 to 0.12 and blank holder force from 120KN to 450KN.

DIE

BLANK HOLDER

PUNCH

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PROJECT GROUP #12

SECOND MODIFICATION IN PROCESS PARAMETERS


Modify Coefficient of friction from 0.12 to 0.10 and blank holder force remains same.

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PROJECT GROUP #12

CAD MODELING

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MATERIAL /COST OPTIMIZATION


Initial blank calculation based on part boundary Blank calculation based on the geometry of the drawing tool Embedding/Nesting

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INITIAL BLANK CALCULATION BASED ON PART BOUNDARY

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BLANK CALCULATION BASED ON THE GEOMETRY OF THE DRAWING TOOL

Punch opening line expanded 20mm


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EMBEDDING/NESTING

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AREAS COVERED
Project Scheduling. Study the Sheet Metal Forming Processes and its

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characteristics. Study Forming and Drawing Dies. Learn CAD/CAM/CAE programs (PRO-E, AUTOFORM). Designing of Draw die using AUTOFORM and PRO/E. Process Simulation using AUTOFORM. Optimize process parameters using software. Material/Cost optimization (Blank calculation and Embedding/Nesting). Manufacturing of Designed die(Scaled) using CAM techniques. PROJECT GROUP #12 Report writing.

THANK YOU

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PROJECT GROUP #12

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