Altair Presentation

Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress

Quality FirstQuality First

TS-16949 Certified Co.

D-U-N-S Number86-246-4013

ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.

A Case Study ofA Case Study ofDie validation of fuel tank usingDie validation of fuel tank using

HyperForm 7.0HyperForm 7.0






ComponentComponent250 mm

350 mm






Material PropertiesMaterial Properties

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

– Young’s Modulus, E : 215000 MPa– Poisson's ratio, nu : 0.26– Yield Stress, σ : 136MPa– Strain Hardening index, n: 0.21– Anisotropy ratio, rbar : 2.31– Strength coefficient, K : 12603 MPa






Stages in simulationStages in simulation

Component

Feasibility Study

Die Face Design

Virtual Tryout Blank Optimizer






Manufacturing Feasibility StudyManufacturing Feasibility Study

Mid surface Extracted






Blank developedBlank developed






Blank profile ( after adding Trimming allowance)Blank profile ( after adding Trimming allowance)






Die FaceDie Face






Virtual Tryout and Blank optimizationVirtual Tryout and Blank optimization

Tool build Process parameters specification

– Tool Motion– Tool Load– Draw bead location– Draw bead parameters– Lubrication

Blank Optimization






Tool BuildTool Build






Iteration 01Iteration 01

Process parameters:– Blank Holding Force : 40 Ton– Friction : 0.125– Draw beads : As per the table (next slide)

Blank shape:






Draw beads ( Iteration 01)Draw beads ( Iteration 01)

BEADS DB1 DB2 DB3 DB4 DB5 DB6 DB7 DB8 DB9 DB10 DB11

DB Height 5 5 5 5 5 5 5 5 5 5 5

DB Rad 5 5 5 5 5 5 5 5 5 5 5

Sh Rad 4 4 4 4 4 4 4 4 4 4 4






Formability plotFormability plot






Next 10 iterationsNext 10 iterationsIT no. Input parameters Results

01 Blank holding force 50 tons, Draw bead parameters 5 x 5 x 4. Die entry radius R20.

Heavy wrinkles till bottom

02 Blank holding force increased to 80 tons.

Wrinkles reduced at straight edges only. Radius portion with heavy wrinkles.

03 Die entry radius at radius portion morphed to R17.5 using Hyper morph.

Wrinkles at radius portion reduced

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 added instead of straight.

Wrinkling tendency reduced but still persisted.

07 Draw bead at radial portions tightened Resulted in crack

08 Blank is chopped off to reduce blank holding force.

Crack vanished but little wrinkling tendency which can be avoided in tryout easily.






Morphing Die Entry Radii locallyMorphing Die Entry Radii locally






Morphing Die Entry Radii locallyMorphing Die Entry Radii locally






Draw beads ( Iteration 02)Draw beads ( Iteration 02)

BEADS DB1 DB2 DB3 DB4 DB5 DB6 DB7 DB8 DB9 DB10 DB11

DB Height 5 5 3 5 5 5 2.5 5 5 5 5

DB Rad 5 5 3 5 5 5 5 5 5 5 5

Sh Rad 2.5 1.98 3 2.4 2.7 2.5 2 3.9 4 3.5 2.4






Formability plotFormability plot






Thinning plotThinning plot






Finished PartFinished Part






Our vision towards Our vision towards CAE…..CAE…..

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

2. Improve upon accuracy level of analysis.2. Improve upon accuracy level of analysis.

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






Thank You….Thank You….

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Altair Presentation