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A Case Study of

Die validation of fuel tank using

HyperForm 7.0

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Component

250 mm

350 mm

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Material Properties
The material grade specified for this fuel tank is IFCS
Material Properties specified by raw material supplier.

Youngs Modulus, E
: 215000 MPa
Poisson's ratio, nu
: 0.26
Yield Stress,
: 136MPa
Strain Hardening index, n: 0.21

Anisotropy ratio, rbar

Strength coefficient, K

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: 2.31
: 12603 MPa

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Stages in simulation

Component
Feasibility Study
Die Face Design
Virtual Tryout

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Blank Optimizer

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Manufacturing Feasibility Study

Mid surface Extracted

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Blank developed

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Blank profile ( after adding Trimming allowance)

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Die Face

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Virtual Tryout and Blank optimization

Tool build
Process parameters specification

Tool Motion
Tool Load
Draw bead location
Draw bead parameters
Lubrication

Blank Optimization

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Tool Build

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Iteration 01

Process parameters:

Blank Holding Force

Friction
Draw beads

: 40 Ton
: 0.125
: As per the table (next slide)

Blank shape:

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Draw beads ( Iteration 01)

BEADS

DB1

DB2

DB3

DB4

DB5

DB6

DB7

DB8

DB9

DB10

DB11

DB Height

DB Rad

Sh Rad

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Formability plot

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Next 10 iterations
IT no.

Input parameters

01

Blank holding force 50 tons, Draw bead

parameters 5 x 5 x 4. Die entry
radius R20.

02

Blank holding force increased to 80 Wrinkles reduced at straight edges only.

tons.
Radius portion with heavy wrinkles.

03

Die entry radius at radius portion Wrinkles at radius portion reduced

morphed to R17.5 using Hyper
morph.

04

Draw bead at straight portion tightened

Wrinkling tendency at straight portion

reduced.

05

Draw beads at radius portion tightened

Resulted in crack

06

At radius profile radial draw beads Wrinkling tendency reduced but still
added instead of straight.
persisted.

07

Draw bead at radial portions tightened

08

Blank is chopped off to reduce blank Crack vanished but little wrinkling
holding force.
tendency which can be avoided in
tryout easily.

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Results
Heavy wrinkles till bottom

Resulted in crack

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Morphing Die Entry Radii locally

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Morphing Die Entry Radii locally

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Draw beads ( Iteration 02)

BEADS

DB1

DB2

DB3

DB4

DB5

DB6

DB7

DB8

DB9

DB Height

2.5

DB Rad

Sh Rad

2.5

1.98

2.4

2.7

2.5

3.9

3.5

2.4

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DB10 DB11

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Formability plot

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Thinning plot

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Finished Part

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Our vision towards

CAE..
1. To cover all forthcoming developments & existing
products
through CAD and CAE.

2. Improve upon accuracy level of analysis.

3. Cover other applications of analysis as well like
PRODUCT
OPTIMIZATION.

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Thank You.

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