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WE8: COPRA® FEA RF 2011; Design OptimisationCopyright © data M Sheet Metal Solutions GmbH . All rights reserved

TopicsTopics

COPRA® FEA RF 2011: Design Optimisation examples

1. Punched profile2. Air bended profile3. Material flow inwards4. Spring back issue5. 3D Profile

New COPRA® FEA RF1. New GUI2. Remeshing3. Parallel option


Important remarks: COPRA® FEA RF 2011 :

is the best tool for experience building and know-how transfer for future generations

will not substitute a good qualified operator, it will make him much better!

results are good as how good the reality can be modeled in the FEA

will SAVE you a lot of MONEY!!


1-Punched profile

Profile

Problem

Problem Quantification

Definitionof causes

Cause:Machine

setting

Cause:RF strategy

Optimisation


Profile

Problem

Problem Quantification

Definitionof causes

Cause:Machine

setting

Cause:RF strategy

Optimisation

Optimisation

One Bend Forming Calibration

Bending Sequence


Profile

Problem

Definitionof causes

Cause:RF strategy

Optimization

Verification

Summary

2-Air bended profile The Problems with the Original Design

Buckling of the long leg due to elongation of the material in the first five stations


Profile

Problem

Definitionof causes

Cause:Machine

setting

Cause:RF strategy

Optimization

Verification

Summary

Optimization: Flower

Flower designed according to the constant-length- method to avoid small radii in the first stations


Profile

Problem

Definitionof causes

Cause:Machine

setting

Cause:RF strategy

Optimization

Verification

Summary

Verification (Main Station 14)

The long arm still tends to buckle, but looks much better than with the original design


3-Material inwards flow difficulty example Rejected Parts Shipped!


FEA Analysis - Station 4BEFORE AFTER

Forming of the ribs: longitudinal strains up to ~2%

Forming of the ribs: longitudinal strains reduced to < 1% using 'trapezoidal forming'


FEA Analysis - Station 10BEFORE AFTER

Necking in the radii on the left side Necking in the radii reduced considerably


Close-Up View – Success!


4- Spring back issue Tube forming / High Strength Steel


Optimized forming strategy

Reduced springback


Optimization R and αD = 120α

= 20°

εz (S01) = 1,07 % !!

D = 120α

= 30°

εz (S01) = 1,12 %

D = 160α

= 20°

εz (max) = 0,87 %

Reason: Negative curvature of the material

D = 160α

= 30°

εz (S01) = 0,96 %


5- 3D Profile 2nd Generation: First Results

There is still a warping of about 3 mm to observe - better than the 1. generation but still too much for an industrial acceptance!


Simulation of Warping Effects

Simulation shows the warping effects (yellow and blue areas) clearly because of stretching and compression zones in the flexible rolled edges of the sheet


COPRA® FEA RF Completely new FEA interface

Windows look and feel Support of Ribbons Compatibility assured


COPRA® FEA RF: Dynamic Remesh

local and global remeshing

remeshing of new bending zones

remesh of „moving“ bending zones

reduction of simulation time

quality increase because of optimal description of bending zone


Definition of length of neutral line by its position through the sheet thickness

0.4 / 0.3 / 0.4 / 0.3 0.4 / 0.3 / 0.28 / 0.24

Further influencing (profile) characteristics:

- Length of outer leg

- Material

- Sheet thickness

Machine:

- Roll diameter

- Roll clearancee.g.:

This defines the location of the mesh refinements to describe the bending zones

Very hard from flat! Remesh required!

Same geometry, but different calculations necessary


Use finer mesh Calculation time increasesIteratively move refinements Analysis time increasesIteratively adapt strip width calculation Analysis time increases

Design quality might increaseRemesh Analysis time decreases

Simulation quality can be increased by:


COPRA® FEA RF: Dynamic Remesh

Remesh

Simulation of round tube

Simulation of

following forming steps (round-to-shape)


COPRA® FEA RF Multi - Processor - Simulation

- 40 %

- 65 %

- 80 %



DiscussionDiscussion and and QuestionsQuestions


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Webinar WE8: COPRA FEA RF 2011: Design · PDF fileWe will be starting soon... Webinar WE8: COPRA ® FEA RF 2011: Design Optimisation. Welcome! Sound is provided via Internet only