KR

Sheet metal forming simulation for
automotive applications
Prof. Dr.-Ing. K. Roll
Summer School Dortmund, 7. September 2012
Outline
Introduction
History of sheet metal simulation
Examples (Springback, Compensation etc.)
Stochastic Simulation
Necessary Developments in Forming Simulation
Refinement of Materials Models
Influence of Anisotropy
Effect of Yield Loci and the Hardening Model
Failure Models
Influence of Temperature
Elastic Tools
Influence of the Press
Metamodels
Simulation of the process chain sheet metal forming
Hemming Simulation
Rollhemming Simulation
Metamodels
Mechanical Joining Simulation
Welding Simulation
Simulation of the part properties (Static, Crash, Fatigue..)
Forming to Crash
Forming to Fatigue
Outlook
Prof. Dr.-Ing. K. Roll Sheet metal forming simulation for automotive applications Sommerschool Dortmund 2012; Slide 2
1
Sheet Metal Forming
Knights Armor (15. Century a. d.) History of sheet metal forming
Source: Prof. Voelkner; TU Dresden
Sheet rolling mill (mid of 19. Century a. d.)

History of sheet metal forming

2
Sheet Metal Forming - History
Production of a front fender

Sheet Metal Forming - today

Production of an engine hood outer
Coil Store Blanking Line Stacking Line
Destacking Line Pressline
3
Chronological development of plasticity theory
computational procedures History of sheet metal forming simulation
Possible simulation techniques in metal forming

History of sheet metal forming simulation
Upper / Lower Bound Methods
Finite Difference Methods
- Static Implicit
Finite Element Methods - Static Explicit
- Dynamic Explicit
Boundary Element Methods
Finite Volume Methods
- Smooth Particle Hydrodynamics

Meshless Methods - Element Free Galerkin Method
- Moving Least Square Method Approx.
- Reproducing Kernel Particle Method
4
Chronological development of plasticity theory
computational FE-procedures History of sheet metal forming simulation
Progress simulation sheet metal forming

B-Column without
Remeshing (1987)
ca. 1400 Elements
(Source: Hora et.al., 1st NUMIFORM)
Front Fender (2001)

ca. 3500 Elements
Source: M. Grber, 1st NumiSheet, Zrich) Deformierte Platine am Ende des Ziehvorganges
5
Progress simulation sheet metal forming
Sidewall with Remeshing

(6 000 000 Elements; 2005)
History of sheet metal forming simulation at Daimler

Year Parts Set-uptime Trial runs
1992 5 3 4 weeks 6-8

1993 8 2 weeks 5
1995 20 1 week 3
1998 >100 <2 days 1-2
2012 >350 < 1.5 days 1-2
Model Size: Die: up to 400.000 Elements

Blank: up to 6.000.000 Elements
Computing Time: from days (1992) to hours on Workstations
or Linux-Clusters
Simulation engineers: 2 in 1992 to 52 in 2011
6
Simulation chain of the complete forming process
Examples of forming simulation
Virtual Die - Making: Engine Hood

7
Finite element model
Binder Blank
Punch
Die
Simulation deep drawing process of an Engine Hood

Initial Position Gravity Holding
25 mm to Final
home position
8
Simulation of sheet forming processes - examples
Hydroforming of sheet metal pairs - Failure modes

9
Surface defects - door handle
Distribution of Thickness [mm]
( 3 %)
Prof. Dr.-Ing. K. Roll two different forming geometries

Sommerschool Dortmund 2012; Slide 19
Sheet metal forming simulation for automotive applications
Surface defects - door handle - Detail

Danger: Better:
compression stress - 0.05 GPa only tensile stress + 0.15 GPa
Minor
Minor stress
stress [GPa]
[GPa] Minor
Minor stress
stress [GPa]
[GPa]
10
Variables influencing springback
springback simulation
Process Conditions Geometry
Forming Process Sheet Thickness

Tool Sheet Dimensions
Force Radius
Tribology Forming Depth
Forming Velocity
Temperature
Variables
influencing
Springback
Material Numerical
Youngs Modulus Time Discretisation

Yield Strength Space Discretisation
Hardening type and size of element
Pre-Treatment Material Model
Plastic Strain Convergence Tolerance
Anisotropy Damping, ...
Springback - Its not a new Phenomena

TRIP 700 ZE
Springback
is ALWAYS existing
DP 500 ZE
arises from stored elastic
forming energy
THM 280 Z
can be reduced
Source:
ZE 340 ZE is depending on
Desired voestalpine
material
Shape Springback of materials process parameters
ZStE180 BK ZE evenly distributed
with constant conditions hardening
11
Two Principle Mechanisms of Springback
Elastic bending stresses Different membrane

through sheet thickness stresses in flanges
After
- +
After plastic
forming
elastic
forming
plastic

Original blank After
- +
shape
After springback
Formed blank
springback
Relaxed blank
Complex Testing Part for the Investigation of

Springback Deviations
AA5182
DP600
H320 LA
AA6016
DC06
12
Possible Forming Processes Using the Testing Tool
Deep drawing Hydro-forming

of the open-ended part of the close-ended part
Deep drawing
of the close-ended part
Computed Springback Results - Material Influence

DC06 H320 LA Displacement

in mm
max. 7,42 mm max. 9,73 mm

AA6016 AA5182
max. 15,67 mm max. 19,02 mm

13
Computed Springback Results
Effect of Forming Technologies
Material: DC06
Deep Drawing Deep Drawing Hydro-

> >>
Open-Ended Close-Ended Forming
max. 6,3 mm max. 4,3 mm max. 0,8 mm
Simulation Sidewall
14
Sidewall Steps of Simulation: Deep Drawing
Sidewall Steps of Simulation: Springback

15
Compensation Program
Part after springback Compensation: Changing the Part after Compensation

Die - Geometry
Software based compensation
CAD-Geometry
Real-Geometry
Die with compensated Geometry

Die
Source: INPRO
Engine Hood Inner - Simulated Springback

3.0 mm
Springback
Deviation
5.0
mm
3.0
Deviations from
desired shape
1.0
Front of part deviates 3.4 mm

upwards along bending line
Maximum: 4.8 mm
Springback nearly
symmetrical to Y Material: AA 6181 A, Thickness: 1.15 mm
16
Compensation of springback - Hood Inner
Savings by simulation-supported Compensation

Overall Cycle Time
OP40 to
One recut of tool set 5 weeks*
OP60 10 weeks*
for compensation
OP20 and
of shape deviations 5 weeks*
OP30
SWF
Each avoided tool recut can Tool building

save between 5 and 10 weeks
in overall cycle time
Time period of die process
engineering is constant, due
to parallel run of simulation Engineering
and die process engineering Today Future
* example: Engine Hood Inner
17
Savings by simulation-supported Compensation
Costs
OP40 to
One recut of tool set 80 T*
OP60 125 T*
for compensation
OP20 and
of shape deviations 70 T*
OP30
SWF
Each avoided tool recut can

saved up to 125 T Tool building
Additional costs of
25 T per tool set during die 25 T
process engineering due to
Engineering
additional human and
computational resources Today Future
* example: Engine Hood Inner
Semi-Automatic Iterative Compensation

Material: TRIP 700

Thickness: 1.4 mm Modifications locally applied on mesh of tools
KDS
Several iterations reduce shape deviations from
CAD-Model (desired shape)
Without Compensation 1. Compensation 2. Compensation
Deviation from CAD-Model

0.0 0.5 mm 1.0
18
Source: Autoform
19
Stochastic Simulation Variation of Parameters
Basic simulation: New Simulation:

AutoForm Final Validation Setup AutoForm Final Validation Setup
Blank: original Blank: smaller
Lube: 0.15 Lube: 0.11; BHkraft: 145t (half)
BHkraft: 145t (half)
Failure Failure
Predictable Variables Using Sheet Metal Forming

Simulation State of the art in sheet forming simulation
20
Simulation vs. Reality
Necessary Developments in Simulation Engineering
Factor Reality Simulation

Production stroke rate Not constant Not in the model
Machine Elastic Not in the model
Tool Elastic Rigid
Characteristics of the direction of draw Not constant Not in the model
Coefficient of Friction Not constant Constant
Temperature Not constant (Not) in the model
Topology of blankholder surface Not constant Not in the model
Material Complex Simple models
Material characteristics Not constant (Not) constant
Components of material modeling for sheet metal

forming
Definition of in-plane transition for elastic

y
to plastic material response
Definition of material work
x hardening based on plastic flow

Defines the correlation of

Yield locus
stress and strain state

xx yx zx xx yx zx

Plastic xy yy zy xy yy zy
hardening xz yz zz xz yz zz

Flow rule
21
Yield Curves - Method of Extrapolation
1,2
DP600
GPa
1
0,8
0,6
DP600_Voce
DP600_Swift
0,4 DP600_Gosh
DP600_Hocket_Sherby
DP600_Ludwik
0,2 DP600_Tensile test
DP600_Layered compression test
0 j
0 0,2 0,4 0,6 0,8 1
Effect of flow-curve approximation on the

simulation result
thickness reduction [%]
Section length [mm]

22
Yield loci models for sheet in-plane anisotropy
A chosen yield locus Hill48

defines the correlation
Barlat89
of yield stress Hill48
depending on the (Barlat89_M2)
Barlat2000
actual stress state and
yy
rolling direction in the Barlat89_M8

sheet
Recentplane.
developments
concentrated on more
MATFEM_A8
and more complex
functions to describe a
constant anisotropy.
xx
Todays choice for material model and failure

prediction
Source: Dr. Kessler; TKS
Numisheet 2008
23
Yield locus models for sheet metal forming
Source: Dr. Kessler; TKS
Numisheet 2008
Yield locus calibration parameters to be determined

24
Yield Surface DP600
Hill 1948 Barlat-Lian 1989 Barlat-Lian 1996
Hill 1979 Simulation

Experiment
Hill 1990
= Combination Hill 48 + Hill 79
Biaxial Stress Factor
Influence of Yield-Loci Model to Failure Description

Source: Heinl, BMW; Dr. Kessler, TKSE; SFU 2010
25
The assumption of isotropic material hardening
The hardening rule specifies the expansion

of the yield locus in case of plastic
deformation.
Isotropic material hardening:
All directions gain the same
hardening x
Monotonic expansion of the

yield locus
y
Industrial aspects of material modeling for steel

grades - Simplification procedure in daily practice
Material hardening Assuming isotropic hardening

1.5 1.5
Normalized stress 22
Normalized stress 22
1.0 1.0
Source: Dr. Kessler, ThyssenKruppSteel
0.5 0.5
0.0 0.0
Numisheet 2008
-0.5 -0.5
-1.0 IYL -1.0 Barlat m=8

SYL SYL
-1.5 -1.5
-1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5
Normalized stress 11 Normalized stress 11
Industrial simulation is mostly based on isotropic hardening!
26
Drawback of the actual modeling method
Modern high strength steel grades may show a stress state dependent
hardening this is hardly to fit with conventional model assumptions
Reasons can be found in phase
Equivalent stress / GPa

transformations or micro-structure 2.0
The up to now used approach with

1.5
constant yield locus and one single
hardening curve can definitely not cover 1.0
U-Tension
these effects! Hydraulic Bulge
0.5 Shear
Do we have alternative modeling options
Stack compression
for industrial simulation tasks?
0.0
0.0 0.1 0.2 0.3 0.4
Equivalent strain / -
Alternative ways for hardening with the

Gen_Yld* model
yy
xx
27
Yield curve comparison for different load paths
3.0 3.0
Isotropic hardening Anisotropic hardening

2.5 Barlat 2000 2.5 Hill 48
2.0 2.0
1.5 1.5
1.0 1.0
0.5 0.5
0.0 0.0
0 0.25 0.5 0.75 1 0 0.25 0.5 0.75 1
Equivalent strain / - Equivalent strain / -
uniaxial tension compression biaxial tension shear
Results in comparison punch force prediction

300
punch force / kN
200
100
experimental Hill48 anisotropic
Yld89 isotropic Yld2000 isotropic
0
0 10 20 30 40 50 60 70
drawing depth / mm
anisotropic hardening approach leads to a better punch force prediction

28
Results in comparison - distribution of major strain
Experimental
0.3
better prediction Hill48 anisotropic
major strain / -
with anisotropic Yld89 isotropic

model
0.2 Yld2000 isotropic
0.1
0.0
0 50 100 150
section length / mm
Material failure due to cracking

Experiment Simulation comparison
Failure Models
29
Prediction of Failure Cross Die (TRIP 700)
Failure Models
Thinning [%]
Failure predicted by numerical thinning
Failure predicted by FLC

Experiment Simulation
A new Model for Failure Prediction and Damage

Failure Models
Correct description of yield locus
Anisotropy
Anisotropic Yield Locus
Forming Simulation
Models: Barlat89, Barlat2000, Hill48, Mat_TRIP
Plastic Strain
Transfer of Variables
Thickness
Damage
Crash Simulation Dynamic Models with Damage
Models: von Mises, Gurson, Gurson-JC
Energy absorption
Prediction of structural folding patterns

30
Failure Models
Concept:
Coupling of a damage model to an unaltered material model

for forming simulations
Forming Crash
material , p, t material
model model
Mapping
with
,p Damage damage
Damage
model
Forming simulation Crash simulation

Failure Models
1.) Using the Gurson

model Barlat , p , thickness
, p
Gurson
Mapping
Gurson Damage f

, p , thickness
Barlat Mapping Mat_024
2.) Using an extended
, p , p
Johnson-Cook model
extended Damage D extended
(GISSMO)
Johnson- Mapping Johnson-
Cook Cook
(GISSMO) (GISSMO)
31
Failure Models
Failure strain vs. Triaxiality (plane stress)

Modification for GISSMO:
Failure strain can be defined arbitrarily
Tabulated input of failure Strain vs. Triaxiality
2,2
2
1,8
1,6
1,4
Failure strain 1,2
f
curve can be 1
determined using 0,8

0,6
coupon tests of 0,4
several distinct 0,2

0
triaxialities -0,2 0 0,2 0,4 0,6 0,8

Failure Models
Simulation of Cross -die formability test using GISSMO coupled to Barlat:
Linear accumulation GISSMO n=2
Real failed part
Failure spot predicted correctly at the

same position
Less damage predicted in areas that are
not close to failure
32
Press Hardening - Process Modeling
Subdivision into Partial Stages
more computational efficiency

use of different time scales
use of different tool models
use of different solvers
Handling
Gravity & Waiting
Forming Quenching
temperature
temperature
temperature
geometry
geometry
(stress, strain)
(stress, strain)
Press Hardening of a roof frame Influence of Temperature
Prediction of Die Temperature
Time after tool closing

1s 4s 8s
33
Press Hardening of a roof frame Influence of Temperature
Prediction of Punch Temperature
Time after tool closing

1s 4s 8s
Press Hardening of a Roof Frame Influence of Temperature
Temperature Change during Forming
34
Thermo-mechanical coupling of sheet forming
processes Influence of Temperature
Forming of XIP-Steel in a cross-die
extrem strain hardening of X-IP-Steel

2,5
X-IP
2,0 TRIP
H320LA
1,5
1,0
Die
0,5
0,0
0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8
Punch
w eq eq dV c p T 0.8 ... 0.9
V

processes
Temperature after Forming - TRIP 700
35
Damaging of TRIP-steel within deep drawing
Cracks after the forming process

36
Forming of Magnesium sheets using a heated tool
Tool with heating system Heated blankholder
Magnesium sheet at 200C Final part: roof inner

Sheet metal forming

Application of different heat treatment methods Influence of Temperature
Without heat treatment With heat treatment
37
Sheet metal forming
Application of different heat treatment methods
Forming simulation
External Subroutine to
introduce heat treatment Ext. Subroutine
Calibration

processes
Conclusion
We need for high-strength steel a thermo-mechanical coupled

simulation in order to respect the temperature distribution in the
sheet during the forming process
We have to respect the Influence of the Temperature in the Material

model
Temperature calculation give information about the thermal load of

the tool
Temperature dependence of the friction must be considered
Heating up of sheet and tool by frictional heat can be considered

38
Elastic tools in the simulation of sheet metal forming
Elastic Tools
local deformations caused by sheet thickening

Consideration of local load application
More accurate simulation of the draw in Rigid model
Variations: Elastic model

1. Models with elastic volume elements
2. Condensation of the tool stiffness on effective areas
Substructuring
3. Modal Analysis
Elastic tool: Example

Elastic Tools
punch
pressure pad
binder
die
elastic plate spacer
die
39
Comparison between rigid and elastic
simulation models Elastic Tools
+0.30
Section
+0.20
+0.10
[mm]
-0,1
Distance along the section [mm]
-0.10
ca. 6,6 mm ca. 6,6 mm
Comparison between rigid and elastic

simulation models Elastic Tools
40
Real Die: Blankholder ca. 7 Mio. Elements
Elastic Tools
Blankholder Surface
Dimensions
2700 x 1660 x 550
Blankholder
pressure: 2,0 N/mm
Structural optimization of tools

Elastic Tools
Original structure Optimized structure (weight reduced)

41
Next Step: Forming simulation with elastic Tools and
elastic Press (ca. 134.000 Volumelements)
Influence of the Machine
Simulation of a Forming Machine with different Loads

(0,5 and 0,92 x nominal Force) Influence of the Machine
42
From process simulation to press line simulation
Process simulation
Rigid die model
Elastic die model
Elastic machine model (static)
Dynamic machine model
Press line simulation
Forming simulation with elastic Tools and elastic Press
Conclusions:
Forming Simulation with elastic Tools increase the accuracy of the
simulation.
Local deformations caused by sheet thickening
Friction Forces are more accurate
Consideration of local load application
More accurate simulation of the draw in
Better calculation of the stresses and deformations of the Tool
Problems:
How we can handle the elastic properties of
Tool and Machine in an economic way?
43
Simulation chain of the complete forming process
Model
Setup
CAD Discretization Tool generation
Forming
Gravity Holding Stamping
Progressive
Processes
Trimming Flanging Hemming Springback
Workflow Sheet Metal Part Production

44
Simulation of the forming process chain
Problems:
Each operating step (drawing, cutting, hemming etc.) need
a own FE - Mesh
Data must be mapped between the FE - Meshes statically and
kinematically compatibly
Simulating the assembly process parts the different FE Meshes
of the parts must be brought by best fit into the correct position.
How we can handle the springback of the assembled part?
In which operation step we have to compensate the springback
of the assembled part?
How can we simulate the influence of the adhesive bonding in the
hemming operation?
Solved Progress ?
Trimming operation (OP30) Trimming Simulation
45
Scrap Flow Simulation Trimming Simulation
Simulation Hemming
Hemming Simulation
hemming of
curved edges
46
Front Fender (Roll in) Hemming Simulation
Experiment vs. Simulation
Frontfender Flange radius Hemming Simulation

Experiment vs. Simulation
47
Rollhemming Rollhemming Simulation
Roller Hemming General procedure

Incremental forming with a roller Inner part
Flange
Application robotically manipulated After flanging
> 90
hemming roller
Hemming bed
Example:
Step 1
~45
Stress in Y [MPa]
Pre-hemming
Hemming roller Roller
Flange Step 2
Final-hemming
Tangential tension stress

Tangential compression
Rollhemming Simulation Rollhemming Simulation
48
Development of a metamodel
Metamodel
Identification of relevant factors by Design of Experiments
flange length prestrain rolling direction
Pareto-Diagramm der standardisierten Effekte Haupteffektediagramm fr REL

Radiuseinsatzlinie (REL) Datenmittelwerte
(Antwort ist REL, Alpha = ,05) Krmmung XY Krmmung Z Blechdicke
2,34
13
C 2,28
D Faktor Name
CE A Krmmung XY
BF 2,22
AD B Krmmung Z
DF
ACF C Blechdicke 2,16
ADE
E
ADF D Abkantradius
2,10
Mittelwert
BC E Falzkanal
F
ABD F Vordehnung
Term
ACD konkav konvex Tiefpunkt Hochpunkt 0,95 1,15

A
AB Abkantradius Falzkanal Vordehnung
CF
AF 2,34
B
ACE
ABC 2,28
EF
CD
BD 2,22
BE
AEF
AC 2,16
AE
DE
2,10
0 500 1000 1500 2000 2500 3000
Standardisierter Effekt 1,0 1,5 0 3 0 10
Generation of response Surfaces

Metamodel
for example, by a sum of weighted

Gauss bells, with the parameter you are
looking for using the method of least
squares
Minimization through local search
Source: FCE Frankfurt Consulting Engineers GmbH
49
Meta model as a basis of a forecast tool for the
planning process of Rollhemming Metamodel
Result forecast based on FEM calculations of rollhemming
Joining: Simulation of Clinch - Process

50
Joining: Simulation of Riveting
Joining: Simulation Tack-setting Mechanical Joining Simulation
51
Joining: Simulation of Spot Welding Welding Simulation
0.75 mm
1 Per. 3 Per.
6 Per. 10 Per.
Processing conditions: flat upper electrode, 2.8 kN, AC1
Processing time: 1, 3, 6,10 periods
Forming to Welding Distortion Welding Simulation
Welding Lines
52
Forming to Welding Distortion
Welding Simulation
Simulation of the part properties (Static, Crash,

Fatigue..)
Simulation of the part properties
Results of the forming

simulation are input for
Crash-analysis
Static analysis
Fatigue analysis
Static analysis
of the tool
Welding distortion
53
Simulation of the part properties (Static, Crash,
Fatigue..)
Simulation of the part properties
Problems:
Each simulation method (static, crash, etc. ) needs a " own " FE - Program
(exception Forming - Crash with explicit codes)
Each simulation method (static, crash, etc. ) needs a own FE - Mesh
Each simulation method has " own " material and failure models
Data must be mapped between the programs statically and kinematically
compatibly.
Today it is only possible to interpolate Scalars such as thickness, plastic
strain, etc.
Which influence does the " damage " have by the mapping process on the
characteristics of the component?
With the extrapolation of Tensors still many questions are open (e.g.: as
equilibrium can be achieved with mapping?)
Solved Progress ?
Coupling Crash - Forming Simulation

Forming to Crash
Today Formingsimulation
Crash- / Staticsimulation (Prototyp Dies)
Styling
Styling Job
Job No..
No. 1 1
Formingsimulation
Forming
Formingsimulation
simulation
(Hard Dies)
Tomorrow
With Forming
History Crash- / Staticsimulation
54
Crash - Forming Simulation - Example
Forming to Crash
Crash Model:
10855 Elements
10759 Nodes
Forming Simulation Modell:

Thickness-Distribution after Mapping
49007 Elements (AUTOFORM)

50285 Nodes
Crash-Forming Simulation
Forming to Crash
Forming properties from 64 parts are mapped to the Crash - Simulation
55
Crash-Forming Simulation
Forming to Crash
Euro-NCAP-Test (deformable Wall): 64 km/h with 40% Overlapping
Standard
With Influence of Thickness
- &
plastic strain
Crash to Forming: Failure and Damage

Forming to Crash
Three Point Bending Test B-column
56
Crash to Forming: Failure and Damage
Forming to Crash
Three point Bending Test B-column
Simulation Simulation
Experiment
without forming with forming
Simulation simulation
Buckling at 82.1 mm
Failure at 196 mm
Barlat + Failure Source: FhG - IWM, Freiburg
Fatigue - Part of the Suspension System

Forming to Fatigue
57
Fatigue - Stress Calculation
Forming to Fatigue
Simulation with Sheet Thickness Classical Simulation with

after the Forming Process Constant Sheet Thickness
+15% +16%
+16%
+16%
+16%
+9%
Fatigue - Failure
Forming to Fatigue
Simulation with Sheet Thickness Classical Simulation with

after the Forming Process Constant Sheet Thickness
+52%
+108%
+47%
1. +108%
2.
+55% 1. 2.
+15%
Ranking List of Failure

58
Trends in Metalforming I
Outlook
Warm forming and hot forming

Press hardening (22MnB5), hot stamping
New lightweight materials (Al, Mg, Ti?)
Hybrid composites (sheet metal / textiles, sheet metal / polymer,
sandwich sheets, sheet metal / fiber-reinforced polymers, )
Tailored (engineered) blanks, bonded blanks, patchwork blanks
special sheets for lightweight design
Aluminum fusion alloys and cladded blanks
Functionally graded materials
Tailored heat treated blanks (Al, 22MnB5)
Cold forming of HSS, AHSS, UHSS
Mechanical joining processes
Servo presses
Special technologies (EMF, superplastic forming,..)
Trends in Metalforming II
Outlook
This has the following consequences for the simulation
Thermal-mechanical coupling will have to be the standard

Heating methods (induction, conduction) will have to be simulated
Tooling properties (thermal, elastic) will have to be considered
Structural optimization of tools and dies will be required
In the long term the system machine-tooling-process will have
to be simulated
The real time has to be used and shown
Development of new, sophisticated material models
Joining technologies for new materials will have to be
simulated as well
Adhesives in mechanical joining processes will have
to be simulated
59
Vision: the future simulation environment
Outlook
;; ;;;;
T
WalzenAnnealing
Rolling Glhen Mapping
Mapping Umformen
Forming Rckfederung
Springback Joining
Fgen Mapping Crash-simulation
Crash-
Kompensation
Compensation
Beurteilung
texture des Beurteilung
yield locus der Beurteilung
depend des
on joining Energyconsumption
Energieaufnahme
Gefges
grain size Herstellbarkeit
hardening Gefges
Technique Intrusion
Entwicklung
Anisotropie
strength in Anisotropie in der
phase transformation Beurteilung
thermal der
wakening Stiffness
Bauteilgeometrie
Dickenrichtung Ebene Wrmeeinflusszone
mechanical Fatigue
transformation damage Div. Anforderungen
Oberflchenqualitt
ductility Umformbarkeit
accuracy etc. hardening aus Crash/Festigkeit/
etc. Welding distortion Steifigkeit
One
Mglichst description
universales, of the material
durchgngiges for all simulations
Materialmodell if possible
oder grtm
gliche Kompatibilitt!
Source: Dr. Haufe, DynaMore
Vision of Digital Factory

Outlook
Not
Not aa single
single production
production facility
facility
will
will Building

be
be planned
planned

be
be built/
built/ Facility
go
go into
into operation
operation
be
be working
working
Line
without
without having
having been
been completely
completely
supported
supported by
by digital
digital planning
planning
methods
methods
Cell
Focus
Focus :: Worker
technical
technical processes
processes
facility
facility components
components Operation
quality
quality
costs
costs Specific
capacities
capacities Process
60
Thank you for your attention!
61

KR

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Sheet metal forming simulation for

Source: Prof. Voelkner; TU Dresden

Sheet rolling mill (mid of 19. Century a. d.)

Source: Prof. Voelkner; TU Dresden

Production of a front fender

Source: Prof. Voelkner; TU Dresden

Sheet Metal Forming - today

Coil Store Blanking Line Stacking Line

Destacking Line Pressline

Possible simulation techniques in metal forming

Upper / Lower Bound Methods

Finite Difference Methods

Finite Volume Methods

- Smooth Particle Hydrodynamics

Progress simulation sheet metal forming

Front Fender (2001)

Sidewall with Remeshing

History of sheet metal forming simulation at Daimler

Year Parts Set-uptime Trial runs

1992 5 3 4 weeks 6-8

Model Size: Die: up to 400.000 Elements

Virtual Die - Making: Engine Hood

Simulation deep drawing process of an Engine Hood

Initial Position Gravity Holding

Hydroforming of sheet metal pairs - Failure modes

Distribution of Thickness [mm]

Prof. Dr.-Ing. K. Roll two different forming geometries

Surface defects - door handle - Detail

Process Conditions Geometry

Forming Process Sheet Thickness

Youngs Modulus Time Discretisation

Springback - Its not a new Phenomena

Elastic bending stresses Different membrane

Complex Testing Part for the Investigation of

Deep drawing Hydro-forming

Computed Springback Results - Material Influence

DC06 H320 LA Displacement

max. 7,42 mm max. 9,73 mm

max. 15,67 mm max. 19,02 mm

Deep Drawing Deep Drawing Hydro-

max. 6,3 mm max. 4,3 mm max. 0,8 mm

Sidewall Steps of Simulation: Springback

Part after springback Compensation: Changing the Part after Compensation

Software based compensation

Die with compensated Geometry

Engine Hood Inner - Simulated Springback

Front of part deviates 3.4 mm

Savings by simulation-supported Compensation

Overall Cycle Time

Each avoided tool recut can Tool building

Each avoided tool recut can

Semi-Automatic Iterative Compensation

Material: TRIP 700

Without Compensation 1. Compensation 2. Compensation

Deviation from CAD-Model

Basic simulation: New Simulation:

Predictable Variables Using Sheet Metal Forming

Factor Reality Simulation

Machine Elastic Not in the model

Tool Elastic Rigid

Characteristics of the direction of draw Not constant Not in the model

Coefficient of Friction Not constant Constant

Temperature Not constant (Not) in the model

Topology of blankholder surface Not constant Not in the model