Sheet Metal Forming II

Simulation Techniques in Manufacturing Technology

Lecture 4
Laboratory for Machine Tools and Production Engineering
Chair of Manufacturing Technology

Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. F. Klocke

WZL/Fraunhofer IPT

Outline
1

Introduction

Simulation of Sheet Metal forming

Case Study

Economical aspects of process modelling

WZL/Fraunhofer IPT

Seite 2

Historical development of the FEM

230 v.Chr.: Calculation of the Pi-number and the
circumference by adding of finite number of
filaments (Archimedes of Syrakus)
1851:

Solution of the minimal area problem by

Schellbach

1909:

Introduction of the Ritz solution method

1915:

Introduction of the weighted residual solution

method by Galerkin

1943:

Introduction of the variation solution method

by Courant

1960:

The terminology Finite Element Method first

used by Clough

ab 1970:

Development of the first commercial FEsoftware

Archimedes

Galerkin

Courant

time

Ritz

Source: Domenico Fetti, Columbia Encyclopedia

WZL/Fraunhofer IPT

Seite 3

Why process modelling?

Increase quality

Manufacture complex parts

Increase reliability
of production
Reduction of time
required for training

Reduction of lead
time

Quality

Car Body
Time

Cost

Reduction of
pre production trials

Apply new materials

(Al, Mg, )
Use material more
efficiently

Reduction of tool
cost

Source: BMW
WZL/Fraunhofer IPT

Seite 4

Design
of car
exterior

Software solution

Application

Process chain

Integration of process modelling into the process chain

Part
design

Means of production
Planning

Tool design

Tool manufacturing
and testing

Part
production

Sheet metal forming simulation

Part evaluation

Process optimisation

Methods applied:

Methods applied:

- 2D modelling
- one-step modelling
- modelling with membrane elements
Short computation time with sufficient
precision

- Simulation with membrane elements

- Simulation with shell elements
High Precision within acceptable
computation times

Source: BMW
WZL/Fraunhofer IPT

Seite 5

Outline
1

Introduction

Simulation of Sheet Metal forming

Case Study

Economical aspects of process modelling

WZL/Fraunhofer IPT

Seite 6

Commercial FE codes for sheet metal forming

2D Modelling of selected cross sections:
Abaqus

www.abaqus.com

Ansys

www.ansys.com

Autoform 2D www.autoform.ch

Advantages:
reduced computation time
less sensitive to quality of input
data

Deform 2D

www.deform.com

Marc

www.marc.com

Disadvantages:
difficult selection of cross sections
to be modelled
less accurate results

usually less input data required

Source: BMW / Fontana Pietro SPA
WZL/Fraunhofer IPT

Seite 7

Commercial FE codes for sheet metal forming

One-step simulation:
Isopunch
SIMEX
Corps
AutoForm Onestep
...

Advantages:
reduced computation time
usually less input data required
suitable tool for part evaluation

Disadvantages:
decreasing significance due to
increasing computing power
still not very accurate

Source: BMW
WZL/Fraunhofer IPT

Seite 8

Commercial FE codes for sheet metal forming

Model with membrane elements:
AutoForm Incremental
Abaqus
...

Advantages:

Source: BMW

Disadvantages:

acceptable computation time

long computation time

suitable tool for part evaluation

problems when severe bending occurs

suitable for process optimisation

not accurate enough in predicting wrinkles

basically accurate results

requires high quality input data

WZL/Fraunhofer IPT

Seite 9

Commercial FE codes for sheet metal forming

Model with shell elements:
PAM-STAMP
Optris
DYNA-Form
Indeed
...

Advantages:
state of the art tools for process
optimisation
very accurate results

Disadvantages:
long computation time leads to long
response time
requires high quality input data

Source: BMW
WZL/Fraunhofer IPT

Seite 10

Outline
1

Introduction

Simulation of Sheet Metal forming

Case Study

Economical aspects of process modelling

WZL/Fraunhofer IPT

Seite 11

Procedure of FE-Analysis
CAD-model

Idealization
Pre-processor

Diskretization
Boundary
conditions

Solver

FE-Analysis

Post-processor

Interpretation of
the results

WZL/Fraunhofer IPT

11

22
12 =

23
13

G11
G
12
0

0
0

G12

G 22
0
0

0
G33
0

0
0
G 23

0 11
0 22

0 12

0 13
G13 23

Seite 12

Material Laws
Low accuracy / low calculation time

Deduction of the modelling parameters

from experimental data:

Elastic

Modelling of the material behavior based

on mathematical material laws

Ideal-plastic

Elastic material behavior: Youngs Modulus,

Poissons ratio, elastic anisotropy
Plastic material behavior: flow curve, strain
hardening parameter, plastic anisotropy

Usage of ideal-plastic material models are

mostly sufficient for bulk forming

Elastoplastic with Plastic with

strain hardening strain hardening

Usage of elastoplastic material models in

sheet metal forming simulations
Consideration of plane anisotropy for sheet
metal forming simulations

High accuracy / high calculation time

WZL/Fraunhofer IPT

Seite 13

Friction laws in metal forming

R
Coulomb friction

Coulomb friction:

R = N

Shear friction

Shear friction:

R = m k

Reality

with

k=

kf
3

Wanheim and Bay developed a more general

friction law with a continuous transition of the
two friction laws mentioned above:

R = f k
Orowan
Reality

Shaw /
Wanheim und Bay

N
WZL/Fraunhofer IPT

Normal stress

Shear stress

,m Friction coefficients
f

Friction factor

Ratio of the contact areas

Seite 14

Part Evaluation: One step method

Steps:
1) Create mesh from 3D
CAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results

Source: BMW
WZL/Fraunhofer IPT

Seite 15

Part Evaluation: One step method

Steps:
1) Create mesh from 3D
CAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results

Source: BMW
WZL/Fraunhofer IPT

Seite 16

Part Evaluation: One step method

Steps:
1) Create mesh from 3D
CAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results

Source: BMW
WZL/Fraunhofer IPT

Seite 17

Part Evaluation: One step method

Steps:
1) Create mesh from 3D
CAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results

Source: BMW
WZL/Fraunhofer IPT

Seite 18

Part Evaluation: One step method

Steps:
1) Create mesh from 3D
CAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results

Source: BMW
WZL/Fraunhofer IPT

Seite 19

Part Evaluation: One step method

Steps:
1) Create mesh from 3D
CAD model
2) create blank holder
3) simplified add-on
4) computation
5) interpretation of results

Source: BMW
WZL/Fraunhofer IPT

Seite 20

Contact stress distribution for circular tool geometry

Contactstresses
N / MPa
400

A-A
drawing direction

300
Contact concentration

200
A-A

Punch force FSt / kN

70
FSt,max = 64,5 kN

0
100

Stroke s / mm

35

Anisotropy effect
0

WZL/Fraunhofer IPT

Seite 21

Alternative tool geometries

Contackt
stresses
N / MPa
400

Lam (a = 10 mm; b = 8 mm; n = 4)

Lam (a = 12 mm; b = 7 mm; n = 3)

FSt,max = 64,5 kN
FSt,max = 61,8 kN
FSt,max = 61,8 kN
FSt,max = 60,1 kN
FSt,max = 63,1 kN

300

200

Lam (a = 10 mm; b = 7 mm; n = 3)

100

0
Lam (a = 10 mm; b = 8 mm; n = 3)

WZL/Fraunhofer IPT

Punch force FSt / kN

70

Stroke s / mm

35

Seite 22

Reduction of stress concentration and wear using the Lam-curve

Contact stress
N / MPa
direction of pull

Areas with
increased
contact stress

Circle-curve
WZL/Fraunhofer IPT

direction of pull

gradually
increasing
contact stress

Lam-curve
Seite 23

Process optimisation: Forming process

CAD-data
tool & blank

Process
boundary
conditions

Contact
formulation

Materialdata

Meshing

GENERIS

PAM-STAMP Input file

WZL/Fraunhofer IPT

Seite 24

Process optimisation: Forming sequence

Source: BMW
WZL/Fraunhofer IPT

Seite 25

Case study: Process optimisation by improved tool design

Part geometry

Tool geometry (cut view)

Workpiece end geometry

Initial workpiece geometry

Tool geometry

Source: BMW
WZL/Fraunhofer IPT

Seite 26

Process optimisation: Forming sequence

Source: BMW
WZL/Fraunhofer IPT

Seite 27

Process optimisation: Forming sequence

Source: BMW
WZL/Fraunhofer IPT

Seite 28

Process optimisation: Forming sequence

Source: BMW
WZL/Fraunhofer IPT

Seite 29

Process optimisation: Forming sequence

Source: BMW
WZL/Fraunhofer IPT

Seite 30

Process optimisation: Forming sequence

Source: BMW
WZL/Fraunhofer IPT

Seite 31

Process optimisation: Forming sequence

Source: BMW
WZL/Fraunhofer IPT

Seite 32

Case study: Evaluation of wrinkling

distribution of effective strain during and after the drawing process

Source: BMW
WZL/Fraunhofer IPT

Seite 33

Process optimisation: Evaluation of wrinkling

distribution of effective stress during and after the drawing process

Source: BMW
WZL/Fraunhofer IPT

Seite 34

Process optimisation: Comparision between simulation and real part

wrinkling
Source: BMW
WZL/Fraunhofer IPT

Seite 35

Process optimisation: Comparision between simulation and real part

rupturing
Source: BMW
WZL/Fraunhofer IPT

Seite 36

Outline
1

Introduction

Simulation of Sheet Metal forming

Case Study

Economical aspects of process modelling

WZL/Fraunhofer IPT

Seite 37

Modelling sheet metal forming: Quality of the computed results

Quality

Result
qualitatively

WZL/Fraunhofer IPT

quantitatively

rupture

++

wrinkles

++

++

springback

Seite 38

Flow chart of a modelling project

Part design

Part
geometry

Boundary Conditions

Material
selection

Tools
(CAD)

Process
parameters

Simulation

Simulation

Start tool
design

yes

no

WZL/Fraunhofer IPT

Seite 39

Effort for a sheet metal modelling project

Change of

responsible

effort CAD

effort Simulation

Process parameters
(friction, beads, ...)

Process design

----

1h --3h

die setup (blank holder,

etc. ...)

Process design

1d -- 1w

3h -- 1d

Material quality and

thickness

Body design

----

1h -- 3h

Part geometry

Body design

1d --1w

3h -- 1d

Total effort for a medium sized part: Usually 2 weeks

WZL/Fraunhofer IPT

Seite 40

Preprocessing effort for a modelling project in sheet metal forming

3W

2W

1W

1993

2009
Effort for preprocessing

WZL/Fraunhofer IPT

Seite 41

Development of computing power and computation time

100%
50h

15h

20%

1993
Increase of computing power

WZL/Fraunhofer IPT

2009

1993

2009
Reduction of computation
time for a large car body
part
Seite 42

Development of hardware cost

100 %

<1%

1993

2009
Hardware cost

WZL/Fraunhofer IPT

Seite 43

Prerequisites for the industrial application of process modelling

Time:
Short response
times

Cost:

Quality:

Low project
cost

Reliable results

Integration into the process chain of a

car body

WZL/Fraunhofer IPT

Seite 44

Simulation of crashworthiness for the Ford Explorer (LS-Dyna)

Source: Livermore Software Technology

WZL/Fraunhofer IPT

Seite 45