Forming Simulation of Front Hood of a Missile  Abhishek Kumar                Ch. Venkateswarlu           B. Shiv Dayal Rao...
Fig.1 shows the CAD Model of front hood. It is fastened with the missile section using screws. Front hood ismade up of mar...
PUNCH                                                                                        DIE                          ...
Figure 5: FLD Plot                  Force vs Time Plot                                           Formed Front Hood        ...
Benefits Summary:The software helped in gaining confidence on the forming process and its various parameters.Challenges :H...
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Mfg 02 forming_simulation_of_front_hood_of_a_missile_drdo

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Mfg 02 forming_simulation_of_front_hood_of_a_missile_drdo

  1. 1. Forming Simulation of Front Hood of a Missile Abhishek Kumar Ch. Venkateswarlu B. Shiv Dayal Rao Dr. K Ramesh Kumar Scientist ‘C’ Scientist ‘D’ Scientist ‘F’ Scientist ‘G’ DRDO DRDO DRDO DRDO Kanchanbagh Kanchanbagh, Hyderabad Kanchanbagh Kanchanbagh, Hyderabad Hyderabad Hyderabad Keywords: Forming, Maraging Steel, HyperForm, Simulation The paper deals with forming simulation of front hood. The front hood is one of the criticalcomponents of the missile and houses the bunch of wires which communicates the electric signals from onesection of the missile to another. It is made up of maraging steel and having the thickness of 0.8mm.Simulation was carried out using HYPERFORM to predict the tonnage requirement and zones of thinningand wrinkling. The good correlation is found between simulated results and actual formed component.Introduction Front hood plays a very important role in proper functioning in the missile. It covers the cables whichrun along the different sections on the missile. These cables connect the different electronic componentshoused inside the missile during the flight. Thus, the protection of cables is very essential and should not beneglected at any cost. Front hood safeguards the cables from external aerodynamic loads and protect themagainst kinetic heating. At the same time, the shape of conduits should be aerodynamically friendly so thatthey should not cause additional drag to the missile. Figure 1: Front HoodSimulation Driven Innovation 1
  2. 2. Fig.1 shows the CAD Model of front hood. It is fastened with the missile section using screws. Front hood ismade up of maraging steel material and having the sheet thickness of 0.8mm. Maraging steel is an ultrahigh strength material and commonly used in defence industry. The limiting factor in design process of sheetmetal components is the necessity of producing the desired shape without any cracks or wrinkles. Theaerospace industries are growing rapidly and the demand for precise and accurate information concerningparts design and formability of metal sheet becomes essential. Sheet metal forming simulation plays anindispensable role in integrating manufacturing necessities into the product design process at an earlystage. The objects of this works will focus on simulating the forming process using HyperForm module ofHyperWorks Software in order to come up with a clear and better understanding of metal flow of sheet metalforming process.Process MethodologyCAD model of Die, Punch are modeled using Solidworks software. Figure 2 illustrates the assembly formingset up. . It consists of base plate punch (for holding the punch), punch, die and base plate of die (for holdingthe die). The Solid models of press tools (die and punch) are imported to the HyperForm and outermost skinprofiles are extracted. These extracted surfaces act as die and punch for sheet metal forming simulation.The front hood is modeled as a sheet metal component. The Blank size is calculated analytically by usingconstant volume criterion. The material properties of maraging steel are obtained using tensile testspecimens. The planar anisotropy also known as plastic strain ratio is calculated by conducting the separatetensile tests as per prescribed ASTM standards. Figure 2: Tool AssemblyThe process is modeled as close as possible to the actual process. Fig. 3 shows the model set up inHYPERFORM.Simulation Driven Innovation 2
  3. 3. PUNCH DIE BLANK Figure 3: Model Set Up in HYPERFORMResults & DiscussionsThe simulated results and actual formed component are shown in the figure 4. The thickness plot indicatesthe probable zones thinning and wrinkling. The formed component is also having the similar wrinkling andthinning zones. The maximum thinning is 10 percent and wrinkling of 8 percent. Wrinkling Zones Figure 4: Percentage thinning plotThe forming limit diagram (FLD) as shown in figure 5, clearly indicates that the process is completely safeand does not result into any tearing. The maximum load acting on the punch is approximately 20 Tons.Figure 6 shows the tonnage requirement with respect to time.Simulation Driven Innovation 3
  4. 4. Figure 5: FLD Plot Force vs Time Plot Formed Front Hood Figure 6: Force vs Time Plot and Formed Front HoodSimulation Driven Innovation 4
  5. 5. Benefits Summary:The software helped in gaining confidence on the forming process and its various parameters.Challenges :HYPERFORM should have database of aerospace materials such as maraging steel etc. and mustincorporate tonnage requirement in the incremental analysis.Future Plans:The similar procedure can be extended for similar type of the component made up of ultra high str strengthmaterial.Conclusions:The use of HyperForm simulation gave the better understanding of forming operations and it has provided ormefficient way to determine important process parameters and helped in minimizing the tool tryouts. Thispaper presented a simulation study concerning the sheet metal forming process and its evaluation usingFLD. ACKNOWLEDGEMENTSThe authors would like to thank Karthik Guda, DesignTech, Hyderabad, and Yogesh Altair Engineering for Yogesh,his active technical support. The authors would also like to thank Dr. D R Yadav ScG for their continuoussupport and encouragement to carry out this activity.Simulation Driven Innovation 5

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