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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

: 2.31 : 12603 MPa

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Stages in simulation

Component

Feasibility Study
Die Face Design Virtual Tryout 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 DB Height

DB1 5

DB2 5

DB3 5

DB4 5

DB5 5

DB6 5

DB7 5

DB8 5

DB9 5

DB10 5

DB11 5

DB Rad Sh Rad

5 4

5 4

5 4

5 4

5 4

5 4

5 4

5 4

5 4

5 4

5 4

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Formability plot

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Next 10 iterations
IT no. 01 Input parameters Blank holding force 50 tons, Draw bead parameters 5 x 5 x 4. Die entry radius R20. Results Heavy wrinkles till bottom

02 03

Blank holding force increased to 80 Wrinkles reduced at straight edges only. tons. Radius portion with heavy wrinkles. Die entry radius at radius portion Wrinkles at radius portion reduced morphed to R17.5 using Hyper morph.
Draw bead at straight portion tightened Draw beads at radius portion tightened Wrinkling tendency at straight portion reduced. Resulted in crack

04 05 06 07 08

At radius profile radial draw beads Wrinkling tendency reduced but still added instead of straight. persisted. Draw bead at radial portions tightened Resulted in crack

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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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

DB10 DB11

DB Height
DB Rad Sh Rad

5
5 2.5

5
5 1.98

3
3 3

5
5 2.4

5
5 2.7

5
5 2.5

2.5
5 2

5
5 3.9

5
5 4

5
5 3.5

5
5 2.4

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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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