Consideration of uncertainties in forming simulation using HyperWorks

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Consideration of uncertainties in forming simulation using HyperWorks

  1. 1. WWW.DTE-ONLINE.DEp.1WWW.DTE-ONLINE.DEDTE2013 European Altair Technology ConferenceConsideration of uncertainties informing simulation usingHyperWorksMarkus Reinert, DTE-VerfahrenstechnikENGINEERINGSIMULATIONMETHOD PLANNINGDESIGNKINEMATICS
  2. 2. WWW.DTE-ONLINE.DEp.2 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-691. Introduction2. Problem Definition3. Discussion4. Conclusion5. Acknowledgements6. ReferencesAgenda
  3. 3. WWW.DTE-ONLINE.DEp.3 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-691. Introduction•DTE was founded in 2000•24 employees in two locations Olpe andHamburg in Germany•Complete service in the field of sheet metalforming tools, mainly automotive•Only software not hardware:• Engineeringsimulation; process planning;feasibility studies; kinematical studies• Tool designingtransfer tools; progressive toolsDTE Werkzeug and Verfahrenstechnik GmbH&Co. KGDesignToolEngineering
  4. 4. WWW.DTE-ONLINE.DEp.4 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-69Manufacturing Process1. Introduction(Drawing)(Cutting)(Cutting)(Calibrating)(Punching)Drawing and SpringbackSimulation with help of•How to get a ready automotive sheet metal part out of a flat coil•Create a Manufacturing Process with the help of CAD•Simulation (FEM) is a helpful tool to ensure the feasibility of your Process
  5. 5. WWW.DTE-ONLINE.DEp.5 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-691. IntroductionDrawing Simulation (FEM)Die geometries out of CADPreprocessing of theSimulation with HyperFormSimulation with Radioss-SolverForming Parameters•Sheet material data•Friction•Forces•Velocities•Drawing Clearance•Etc.
  6. 6. WWW.DTE-ONLINE.DEp.6 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-69Drawing Simulation in engineering phasePut results and information out ofthe simulation into the ProcessplanPut changed Forming-Geometriesand -Paramters into the simulationSpringbackFLDThinning1. IntroductionPostprocessing of the Simulationwith HyperView:Change Geometries in CAD:•Drawing radius•Die design•Blank geometries•Whole processChange Forming Parameters inPreprocessing :•Forces•Meshing Parameters•Draw beads
  7. 7. WWW.DTE-ONLINE.DEp.7 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-692. Problem DefinitionLightweight with high strength steels and aluminumIn the automotive industry, the lightweight isan increasingly important issue. This leadsto the increased use of high strength steelsand aluminum. These materials decreasethe process capability of forming of manyautomotive components than conventionalmaterials. It becomes more difficult topredict the feasibility of CAE methods.The feasibility regionis getting smaller
  8. 8. WWW.DTE-ONLINE.DEp.8 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-692. Problem DefinitionSimulation (CAE) is a Model of realityThere are many influential parametersmaterial quality•Material data and flow curve (tensilestrength, yield strength, modulus ofelasticity, …)•Anisotropy (rollingdirection, r-values)•Thickness•Tribology (surface of the sheet)•Blank geometry•Trim lines hardening•etc.Influenz on feasibilityInfluenz on springback
  9. 9. WWW.DTE-ONLINE.DEp.9 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-692. Problem DefinitionSimulation (CAE) is a Model of realityThere are many influential parametersphysical parameters•Friction (die, binder)•Binder force•Forming geometries(Drawing radius, clearance, …)•Press parameters(drawing velocity, pressing force during time,tilting and deflection of press ram)•Temperature•Lubrication•Drawbeads•etc.Influenz on feasibilityInfluenz on springback
  10. 10. WWW.DTE-ONLINE.DEp.10 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-69More Problems2. Problem DefinitionMaterial change• From Plate-Material to Coil-Material• From one Material batch to another batchPress change• From Tryout Press to Serial Press• From Serial Press to Replacement PressTrim lines hardening on aluminum• After cutting process there is a secondforming process•Crack failure on bending trim lineFluctuation on material qualityFluctuation on physical parameters
  11. 11. WWW.DTE-ONLINE.DEp.11 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-692. Problem DefinitionSimulation (FEM) is a model of realityRealitySimulation FEMProblem•Simulation is OK•First tryout is OK•After changing the coil in real process thereare cracks!•Why there are cracks? How we will be ableto make the process safety?
  12. 12. WWW.DTE-ONLINE.DEp.12 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-69How to deal with the uncertaintiesLook critically on your Simulation Results• are the results plausible• compare your results with reality (ex post analysis)Look at other results than Thinning and FLD• plastic strain• look at results over forming timeIntegrate other Failure Model into Simulation• Johnson Cook FailureSensitivity Analysis• Study of the fluctuation of Forming Parameters using HyperStudy,Design of Experiments (DoE)3. Discussion
  13. 13. WWW.DTE-ONLINE.DEp.13 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-693. DiscussionOther results (Plastic Strain along thickness)Detect significant areas:•It mustnt means there is a Crack or Failure•Have a look at detected Elements at the restof Simulation-Analysis
  14. 14. WWW.DTE-ONLINE.DEp.14 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-693. DiscussionResults over forming time (FLD)At the end ofSimulation:•TensileAt the beginning ofSimulation:•Compression
  15. 15. WWW.DTE-ONLINE.DEp.15 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-69Failure Model Johnson Cook3. DiscussionCrack like realityNo cracks in reality(>> use this FailureModel carefully!)How to determine D1, D2, D3 Parameters(Excel List by Altair):•Method of least squares to fit the rupture strain given byfunction to experimental data (tension, compression, shear)
  16. 16. WWW.DTE-ONLINE.DEp.16 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-69HyperStudy; Design of Experiments (DoE)3. DiscussionFluctuating Parameter(Design variables):• Blank Thickness: ±10%• Flow Curve: ±10%• Binder Force: ±30%• Die/Binder Friction: ±50%HyperStudy at the end of Engineering and Simulation Process!Detect critical nodes out of HyperView(Responses):• Response 1-5: max. plastic Strain or five nodes• Response 6-10: min. thickness for same five nodesFull Factorial DoE class:• Each min. and max. Design variable with each other>> 32 runs
  17. 17. WWW.DTE-ONLINE.DEp.17 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-694. Conclusion•Safety and robust manufacturing processes•Reduction of Tryout Time and Tryout Problems•Less waste in manufacturing processes•Better Part Quality•Less Costs in later product life cycleSimulation by using HyperWorks and spend more time,knowhow and money in CAE brings benefits
  18. 18. WWW.DTE-ONLINE.DEp.18 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-69Thanks to ALTAIR Germany for Software andProblem SupportI especially thank Mr. Trickov for his personalcommitment5. Acknowledgements
  19. 19. WWW.DTE-ONLINE.DEp.19 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-69ALTAIR, ”Reference Guide”, Altair 2012V. Trikov, “Johnson Cook Failure”, Altair 2012C. Held, R. Schleich, M. Sindel, M. Liewald, “Untersuchungen zumEinfluss der Verfestigung von schergeschnittenen Kanten auffolgende Umformprozesse,“ UTFscience 2/20096. References
  20. 20. WWW.DTE-ONLINE.DEp.20 DTE Verfahrenstechnik Gmbh&Co.KG • In der Trift 57 • D-57462 Olpe • Telefon: +49(0)2761 9024-61 • Telefax: +49(0)2761 9024-69Thank You for Your attention!Q & A

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