PROJECT GROUP #12 BATCH 2006-07 KASHIF ASHHAR ARSALAN ZAHEER M.
FAYZAN SYED WAQAS ALI (031) (032) (059) (060)
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OBJECTIVEAPPLICATION OF NUMERICAL MODELING AND SIMULATION IN
DESIGNING OF SHEET METAL DIES
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INTRODUCTION
Flow chart of process planning and die design in traditional CAD
environment
Workflow in simulation based process planning and die design
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PROJECT GROUP #12
PARTMATERIALSACE 120 CR-DDQ-AL (JISG3314) (ASTM A 463)
Protector, Fuel tank (Corolla -242L)
THICKNESS0.5 mm
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PHASE IIIMODELING & SIMULATIONOne step AnalysisTo conclude
simply whether a product as designed is formable with ease, &
if not, to identify areas on the geometry that lead to formability
issues
Starting Final product geometry only with: Sheet Thickness
Material Specifications Setting Parameters Die Tip Lubrication Edge
Restraint Conditions5 PROJECT GROUP #12
ONE STEP ANALYSIS RESULT(Geometry 1)
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Forming Limit Diagrams (Geometry 1)
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Forming Limit Diagrams (Geometry 2)
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INCREMENTAL ANALYSISA Full process model that simulates the
forming stages as accurately as possible in logical order from
blank holder closing to final flanging. With Capabilities to
Analyze: Initial Deflection of Sheet due to gravity Blank holder
Closing First Draws and Restrikes Cutting Operations Sheet
Repositioning Flanging and Springback Hydro-Mechanical processes
for Sheets and Tubes
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FIRST CONCEPT
CAD Surface geometry Of Fuel tank protector
Boundary Fill(brown),Binder(reddish brown) and Addendum ( green)
created with Autoform Die Designer
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PRESS TONNAGECALCULATIONS:
PUNCH :DIE
From graph: Punch force = 300kN By rule of thumb: (300kN)(2.5) =
750kN = 75tonn(approx) BLANK HOLDER: From graph: blank holding
force = 120kN By rule of thumb: (120kN)(2.5) = 300kN =
30tonn(approx) PRESS TONNAGE; Press tonnage = punch force + blank
holding force = 75tonn + 30tonn = 105tonnPUNCH BLANK HOLDER
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INCREMENTAL ANALYSIS
SECOND CONCEPT
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Location of Wrinkles Planar/Flat areas Curved areas Areas under
binder
Threshold value0.001 0.02 0.05
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FIRST MODIFICATION IN PROCESS PARAMETERSModify Coefficient of
friction from 0.15 to 0.12 and blank holder force from 120KN to
450KN.
DIE
BLANK HOLDER
PUNCH
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SECOND MODIFICATION IN PROCESS PARAMETERSModify Coefficient of
friction from 0.12 to 0.10 and blank holder force remains same.
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CAD MODELING
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MATERIAL /COST OPTIMIZATION Initial blank calculation based on
part boundary Blank calculation based on the geometry of the
drawing tool Embedding/Nesting
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INITIAL BLANK CALCULATION BASED ON PART BOUNDARY
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BLANK CALCULATION BASED ON THE GEOMETRY OF THE DRAWING TOOL
Punch opening line expanded 20mmPROJECT GROUP #12
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EMBEDDING/NESTING
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AREAS COVERED Project Scheduling. Study the Sheet Metal Forming
Processes and its
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characteristics. Study Forming and Drawing Dies. Learn
CAD/CAM/CAE programs (PRO-E, AUTOFORM). Designing of Draw die using
AUTOFORM and PRO/E. Process Simulation using AUTOFORM. Optimize
process parameters using software. Material/Cost optimization
(Blank calculation and Embedding/Nesting). Manufacturing of
Designed die(Scaled) using CAM techniques. PROJECT GROUP #12 Report
writing.
THANK YOU
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