PROJECT GROUP #12 BATCH 2006-07

KASHIF ASHHAR ARSALAN ZAHEER M. FAYZAN SYED WAQAS ALI (031) (032) (059) (060)

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OBJECTIVE
APPLICATION OF NUMERICAL MODELING AND SIMULATION IN DESIGNING OF SHEET METAL DIES

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INTRODUCTION

Flow chart of process planning and die design in traditional CAD environment

Workflow in simulation based process planning and die design

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PART
MATERIAL
SACE 120 CR-DDQ-AL (JISG3314) (ASTM A 463)

Protector, Fuel tank (Corolla -242L)

THICKNESS
0.5 mm

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PHASE III
MODELING & SIMULATION
One step Analysis
To conclude simply whether a product as designed is formable with ease, & if not, to identify areas on the geometry that lead to formability issues

Starting Final product geometry only with: Sheet Thickness Material Specifications Setting Parameters Die Tip Lubrication Edge Restraint Conditions
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ONE STEP ANALYSIS RESULT(Geometry 1)

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Forming Limit Diagrams (Geometry 1)

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Forming Limit Diagrams (Geometry 2)

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INCREMENTAL ANALYSIS
A Full process model that simulates the forming stages as accurately as possible in logical order from blank holder closing to final flanging. With Capabilities to Analyze: Initial Deflection of Sheet due to gravity Blank holder Closing First Draws and Restrikes Cutting Operations Sheet Repositioning Flanging and Springback Hydro-Mechanical processes for Sheets and Tubes

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FIRST CONCEPT

CAD Surface geometry Of Fuel tank protector

Boundary Fill(brown),Binder(reddish brown) and Addendum ( green) created with Autoform Die Designer

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PRESS TONNAGE
CALCULATIONS:

PUNCH :
DIE

From graph: Punch force = 300kN By rule of thumb: (300kN)(2.5) = 750kN = 75tonn(approx) BLANK HOLDER: From graph: blank holding force = 120kN By rule of thumb: (120kN)(2.5) = 300kN = 30tonn(approx) PRESS TONNAGE; Press tonnage = punch force + blank holding force = 75tonn + 30tonn = 105tonn
PUNCH BLANK HOLDER

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INCREMENTAL ANALYSIS

SECOND CONCEPT

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Location of Wrinkles
Planar/Flat areas Curved areas Areas under binder

Threshold value
0.001 0.02 0.05

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FIRST MODIFICATION IN PROCESS PARAMETERS

Modify Coefficient of friction from 0.15 to 0.12 and blank holder force from 120KN to 450KN.

DIE

BLANK HOLDER

PUNCH

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SECOND MODIFICATION IN PROCESS PARAMETERS

Modify Coefficient of friction from 0.12 to 0.10 and blank holder force remains same.

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CAD MODELING

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MATERIAL /COST OPTIMIZATION

Initial blank calculation based on part boundary Blank calculation based on the geometry of the drawing tool Embedding/Nesting

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INITIAL BLANK CALCULATION BASED ON PART BOUNDARY

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BLANK CALCULATION BASED ON THE GEOMETRY OF THE DRAWING TOOL

Punch opening line expanded 20mm

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EMBEDDING/NESTING

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AREAS COVERED
Project Scheduling. Study the Sheet Metal Forming Processes and its

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characteristics. Study Forming and Drawing Dies. Learn CAD/CAM/CAE programs (PRO-E, AUTOFORM). Designing of Draw die using AUTOFORM and PRO/E. Process Simulation using AUTOFORM. Optimize process parameters using software. Material/Cost optimization (Blank calculation and Embedding/Nesting). Manufacturing of Designed die(Scaled) using CAM techniques. PROJECT GROUP #12 Report writing.

THANK YOU

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