Altair's Student Guides - Instructor's Manual - CAE For Simulation of Sheet Metal Forming
Altair's Student Guides - Instructor's Manual - CAE For Simulation of Sheet Metal Forming
Altair's Student Guides - Instructor's Manual - CAE For Simulation of Sheet Metal Forming
Contents
Introduction.............................................................................................2
Installation Instructions: .......................................................................2
Simulation of Springback in Aluminum.......................................................3
Description of the Problem ....................................................................3
Data Organization .................................................................................4
Building the Tool...................................................................................4
Process Parameters...............................................................................5
The Nonlinear Solution ..........................................................................6
Results and Design Modifications ...........................................................6
Further Work ........................................................................................7
Summary .............................................................................................8
Blank Size Optimization for an A-Pillar .......................................................9
Description of the Problem ....................................................................9
Data Organization ............................................................................... 10
Building the Tool................................................................................. 10
Process Parameters............................................................................. 11
The Nonlinear Solution ........................................................................ 12
Results and Design Modifications ......................................................... 12
Further Work ...................................................................................... 13
Summary ........................................................................................... 13
Optimization of Blankholding Force for a Seat Riser.................................. 15
Description of the Problem .................................................................. 15
Data Organization ............................................................................... 16
Building the Tool................................................................................. 16
Process Parameters............................................................................. 17
The Nonlinear Solution ........................................................................ 18
Results and Design Modifications ......................................................... 18
Further Work ...................................................................................... 19
Summary ........................................................................................... 19
Multi-stage Forming of a Suspension Cover.............................................. 21
Description of the Problem .................................................................. 21
Data Organization ............................................................................... 22
Building the Tool................................................................................. 22
Process Parameters............................................................................. 23
The Nonlinear Solution ........................................................................ 24
Results and Design Modifications ......................................................... 24
Further Work ...................................................................................... 25
Summary ........................................................................................... 26
1
Student Project Summaries CAE for Simulation of Metal Forming
Introduction
This material is best used after reading the book Managing The CAE Process.
To make best use of this material you will need a computer with a sound-
card and speakers. Your computer should have a media-player program
(such as Windows Media Player) and an Internet Browser that supports
JavaScript. The material can be copied to a server and accessed by clients.
Installation Instructions:
1. Copy the folders to your computer or to your server. If you are
working on a server, it is a good idea to set the folders to “read
only” to prevent inadvertent modifications.
2. The videos are best played in full-screen at a resolution of 1024 x
768. You may need to install the CamStudio Codec to view video on
your computer. To do this, right-click on the file camcodec.inf and
choose Install from the popup menu. You may need administrator
privileges to do this.
3. Ensure that JavaScript is enabled on your browser.
4. Each folder contains one HTML file. Double-click on it to open the
instructions.
5. Data files are provided as relevant – IGES files, HM files, etc.
6. In case you need support, contact your distributor or email
[email protected]
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Student Project Summaries CAE for Simulation of Metal Forming
3
Student Project Summaries CAE for Simulation of Metal Forming
Data Organization
The initial data is available as an IGES file. This
includes both the die-surfaces and the blank.
4
Student Project Summaries CAE for Simulation of Metal Forming
Process Parameters
The automatic-process definition options make it
very easy to define all the process parameters,
but it is important to take care to make sure all
the correct options have been specified! For
instance, the setup requires a single-action press.
5
Student Project Summaries CAE for Simulation of Metal Forming
6
Student Project Summaries CAE for Simulation of Metal Forming
If your students have a good grasp on the mathematics of the finite element
method, they should use the on-line documentation to check for output
measures that help judge the quality of the solution.
Further Work
There are several aspects that can make the project more complete. You
may choose to assign these to your students based on their level of
proficiency, the time available, etc.
You could also suggest to your students that they investigate the effects of
friction. If the die manufacturer can verify the model against an analysis, the
model can be fine-tuned to mimic real-life behavior, then used for what-if
analyses. Since your students are unlikely to have access to a press, they
7
Student Project Summaries CAE for Simulation of Metal Forming
Summary
By the end of this assignment, the student will know how to
8
Student Project Summaries CAE for Simulation of Metal Forming
9
Student Project Summaries CAE for Simulation of Metal Forming
Data Organization
The initial data is available as an IGES file. This
includes both the die-surfaces and the blank.
Since this is the case for this project, the first step
is to check that the IGES geometry is correct – for
instance, to check for gaps in the surfaces, which
is a common occurrence given the finite precision
of many CAD modelers.
10
Student Project Summaries CAE for Simulation of Metal Forming
Process Parameters
The automatic-process definition options make it
very easy to define all the process parameters, but
it is important to take care to make sure all the
correct options have been specified! For instance,
the setup requires a single-action press.
11
Student Project Summaries CAE for Simulation of Metal Forming
12
Student Project Summaries CAE for Simulation of Metal Forming
Further Work
There are several aspects that can make the project more complete. You
may choose to assign these to your students based on their level of
proficiency, the time available, etc.
You could also suggest to your students that they investigate the effects of
friction. If the die manufacturer can verify the model against an analysis, the
model can be fine-tuned to mimic real-life behavior, then used for what-if
analyses. Since your students are unlikely to have access to a press, they
can generate curves showing the variation of process-behavior with the
coefficient of friction.
Summary
By the end of this assignment, the student will know how to
13
Student Project Summaries CAE for Simulation of Metal Forming
14
Student Project Summaries CAE for Simulation of Metal Forming
15
Student Project Summaries CAE for Simulation of Metal Forming
Data Organization
The initial data is available as an IGES file. This
includes both the die-surfaces and the blank.
Since this is the case for this project, the first step
is to check that the IGES geometry is correct – for
instance, to check for gaps in the surfaces, which
is a common occurrence given the finite precision
of many CAD modelers.
16
Student Project Summaries CAE for Simulation of Metal Forming
Process Parameters
The automatic-process definition options make
it very easy to define all the process
parameters, but it is important to take care to
make sure all the correct options have been
specified! For instance, the setup requires a
single-action press.
17
Student Project Summaries CAE for Simulation of Metal Forming
18
Student Project Summaries CAE for Simulation of Metal Forming
Further Work
There are several aspects that can make the project more complete. You
may choose to assign these to your students based on their level of
proficiency, the time available, etc.
You could also suggest to your students that they investigate the effects of
friction. If the die manufacturer can verify the model against an analysis, the
model can be fine-tuned to mimic real-life behavior, then used for what-if
analyses. Since your students are unlikely to have access to a press, they
can generate curves showing the variation of process-behavior with the
coefficient of friction.
Summary
By the end of this assignment, the student will know how to
19
Student Project Summaries CAE for Simulation of Metal Forming
• derive the binder and punch surfaces from the die face
• create draw beads
• choose material models and data from a library
• specify die velocity and range of movement
• apply blankholder forces
• specify the memory used by the solver
• edit the time-of-simulation
• specify the coefficient of friction
• read the simulation “list” files for information on the simulation
• view the animated, large-deformation, plastic deformation of the
blank
• generate thickness contours
• predict tearing and wrinkling
• generate a Forming Limit Curve and the Forming Limit Diagram
• calculate blankholder forces and press tonnage
20
Student Project Summaries CAE for Simulation of Metal Forming
21
Student Project Summaries CAE for Simulation of Metal Forming
Data Organization
The initial data is available as an IGES file. This
includes both the die-surfaces and the blank.
Since this is the case for this project, the first step is
to check that the IGES geometry is correct – for
instance, to check for gaps in the surfaces, which is a
common occurrence given the finite precision of many
CAD modelers.
22
Student Project Summaries CAE for Simulation of Metal Forming
Process Parameters
The automatic-process definition options make it very
easy to define all the process parameters, but it is
important to take care to make sure all the correct
options have been specified! For instance, the setup
requires a single-action press.
23
Student Project Summaries CAE for Simulation of Metal Forming
24
Student Project Summaries CAE for Simulation of Metal Forming
• use the results of the first analysis to estimate the die for the first
stage of forming
• redo the analysis with this "new" design, after making sure the the
"state" file is saved by the previous stage
• use the blank from the first stage as the starting point of the second
stage, by reading the state file
Further Work
There are several aspects that can make the project more complete. You
may choose to assign these to your students based on their level of
proficiency, the time available, etc.
You could also suggest to your students that they investigate the effects of
friction. If the die manufacturer can verify the model against an analysis, the
model can be fine-tuned to mimic real-life behavior, then used for what-if
analyses. Since your students are unlikely to have access to a press, they
can generate curves showing the variation of process-behavior with the
coefficient of friction.
25
Student Project Summaries CAE for Simulation of Metal Forming
Summary
By the end of this assignment, the student will know how to
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