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Process Simulation of Tube Stamping on HyperWorks Platform

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  • 1. Process Simulation of Tube Stamping on HyperWorks Platform2013 European Altair Technology Conference- Turin
  • 2. Happy 23rdApril National Sovereignty and Childrens Day!
  • 3. AGENDAo About Uso About Twist Beamo Advantages and Disadvantages of Twist Beam Processo Forming Analysis of Beamo Conclusions
  • 4. M.Kemal Coşkunöz2012 Turnover :495.26 m.€No. of Employees :320060 YEARS EXPERIENCE IN METAL FORMINGÇOŞKUNÖZ HOLDING
  • 5. COSKUNOZ BUSINESSGROUPCOŞKUNÖZEDUCATIONFOUNDATIONCoskunozDefence &AerospaceA.ŞCoşkunözRadiatorA.ŞCemTransportA.ŞRUBBERBeltanVibracousticA.ŞBetasealsA.ŞBelkaA.ŞMETALCoşkunöz MetalForm A.ŞCoşkunözMA A.ŞAUTOMOTIVE MACHINERY AEROSPACE TRANSPORTHEATING ENERGYCoşkunözSolarA.ŞSınırsızEnerji A.ŞHOLDING COMPANIES
  • 6. MACHINERYGROUPLASERTECHNOLOGIESDEFENCEAEROSPACEAUTOMATIONGROUPTOOLING GROUPAUTOMOTIVEGROUPCAD Catia V5 SolidWorks UniGraphicsFORMING Autoform HyperformFEA HyperMesh Radioss Optistruct Acusolve CFDTOOL KINEMATIC Expressus72R&D CENTERHUMAN RESOURCES SOFTWARES
  • 7. R&D CENTERBenchmarking Data AcquisitionReverse EngineeringOptimizationComputer Aided DesignDurability TestPrototype ProductionComputer Aided Engineering
  • 8. TWIST BEAM- 3 primary forces at tyre contact patch Longitudinal Lateral Vertical- Additional Torque LoadingFrom Braking(Combined with aLongitudinal Force)
  • 9. TWIST BEAM*3COMPONENTS OF CURRENT TWIST BEAM
  • 10. TWIST BEAMSTABILIZERSTABILIZERSUPPORTBRACKETSFASTENERSCOMPONENTS OF CURRENT TWIST BEAM*2
  • 11. TWIST BEAMCOMPONENTS OF A NEW CONCEPT TWIST BEAM*2A new concept twist beam eleminates multiple parts on beam
  • 12. TWIST BEAMADVANTAGESIt reduces ;1- COST ,2- WEIGHT,3- ASSEMBLY TIME,4- CO2 EMMISSION,
  • 13. TWIST BEAMDISADVANTAGES1- COMPLICATED PROCESS ,2- DIFFICULTY ON REPEATIBILITY OF PRODUCT AND PROCESS QUALITY ,
  • 14. TWIST BEAMOLD VERSION NEW VERSIONTotal Weight 20.544 kg 17.485 kgWeight Part w.o.Fasteners20.324 kg 17.220 kgWeight Fasteners 0.220 kg 0.265 kg*2*2
  • 15. Thickness3,2FORMING ANALYSIS OF TWISTBEAMTUBE GEOMETRY MATERIAL PROPERTIESFor Failure Criteria
  • 16. FORMING ANALYSIS OF TWISTBEAM
  • 17. FORMING ANALYSIS OF TWISTBEAMHYPERFORM INCREMENTAL RADIOSS USER INTERFACE
  • 18. FORMING ANALYSIS OF TWISTBEAMFORMING OPERATIONS (OP 10 – PREFORMING PROCESS)
  • 19. FORMING ANALYSIS OF TWISTBEAMFORMING OPERATIONS (OP 20 – V SHAPE FORMING PROCESS)*.STA dataTransferFrom Op 10 to Op20
  • 20. FORMING ANALYSIS OF TWISTBEAMFORMING RESULTSAfter Surface Development Before Surface Development
  • 21. FORMING ANALYSIS OF TWISTBEAMFORMING RESULTS
  • 22. COMPARISON OF RESULTSFORMING ANALYSIS OF TWISTBEAMSURFACE DEVELOPMENT
  • 23. CONCLUSIONS1- It is easy to create a tube stamping finite element model on Hyperworks bypassing through user profiles between block and incremental radioss.2- Hyperworks allows to simulate deformations dependent on self-contact .3- The results from Hyperworks will be compared with the results on prototype.
  • 24. RESOURCES1- Mechanics of Sheet Metal Forming , Z.Marciniak , J.L.Duncan , S.J. Hu2- http:// a2mac1.com3-http://incar.thyssenkrupp.com/5_02_024_a_Light_Duty.html?lang=en
  • 25. Thanks For Your AttentionQUESTIONS & ANSWERSMesut KAYAR&D Supervisormekaya@coskunoz.com.trMetin ÇALLIFEA Responsiblemcalli@coskunoz.com.trYavuz GÖKKUŞR&D Process Responsibleygokkus@coskunoz.com.tr