Static compensation for elastic tool and press deformations during deep drawing

Großmann, Knut; Wiemer, Hajo; Hardtmann, André; Penter, Lars; Kriechenbauer, Sebastian

doi:10.1007/s11740-010-0216-7

Cited by 4 publications

(3 citation statements)

References 2 publications

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“…Previous research and experience points to many advantages if sheet metal forming is simulated with elastic dies [1][2][3][4][5][6][7][8]. Some areas that are enabled by simulations with elastic dies are virtual spotting, improved digital twins, and improved production support.…”

Section: Introductionmentioning

confidence: 99%

Three Industrial Cases of Sheet Metal Forming Simulations with Elastic Dies

Pilthammar,

Sigvant,

Islam

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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Previous research and experience points to many advantages if sheet metal forming is simulated with elastic dies. Some areas that are enabled by simulations with elastic dies are virtual spotting, improved digital twins, and improved production support. A promising method was selected from the literature, and after important modifications it is deemed to be fast and robust for simulating industrial sized dies. The method consists of meshing die solids with a coarse mesh to represent the structural behaviour of the die. The forming surfaces are then represented by a fine shell mesh connected to the solid mesh by tied contacts with an offset. With additional modifications to reduce solver time this yields a robust and flexible way of modelling sheet metal forming with elastic dies. There is an increase in preprocessing and simulation time compared to using rigid tools, but industrial dies can now be modeled within an hour and solved within a working day. It is also easy to update the model by replacing separate parts such as die solids or forming surfaces. One of the main criteria in favor of the selected approach is the realistic modeling of blankholder and cushion systems. In this paper simulations of three industrial cases are demonstrated: one case of virtual die spotting and two cases of production support. The three cases demonstrate the importance and potential of using elastic dies during virtual die tryout, production support, and for cases like digital twins and production control.

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Section: Introductionmentioning

confidence: 99%

Three Industrial Cases of Sheet Metal Forming Simulations with Elastic Dies

Pilthammar,

Sigvant,

Islam

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

View full text Add to dashboard Cite

show abstract

“…Another reason is the lack of die CAD models before the later stages of stamping projects. Previous research during the last couple of decades indicated large benefits if elastic dies and presses are included in SMF simulations [1][2][3][4][5][6][7][8]. The benefits of simulations with elastic tools are also seen in related manufacturing techniques using dies and presses.…”

Section: Introductionmentioning

confidence: 99%

An overview of Methods for Simulating Sheet Metal Forming with Elastic Dies

Pilthammar,

Sigvant,

Islam

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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Sheet metal forming (SMF) simulations are traditionally carried out with rigid active forming surfaces. This means that the elasticity and dynamics of presses and die structures are ignored. The only geometries of the tools included in the simulations are the active forming surfaces. One reason for this simplification is the large amount of computational power that is required to solve finite element (FE) models that incorporates elastic stamping dies. Another reason is the lack of die CAD models before the later stages of stamping projects. Research during the last couple of decades indicated potential large benefits when including elastic dies in SMF simulations. For example, for simulating die try-out or for Digital Twins of presses and dies. Even though the need and potential benefits of elastic dies in simulations are well known it is not yet implemented on a wide scale. The main obstacles have been lacking data on presses and dies, long simulation times, and no standardized implementation in SMF software. This paper presents an overview of existing methods for SMF simulations with elastic dies and discuss their respective benefits and drawbacks. The survey of methods shows that simulation models with elastic tools will be needed for detailed analyses of forming operations and also for purposes like digital twins. On the other hand, simplified and robust models can be developed for non-FEA users to carry out simple one-step compensation of tool surfaces for virtual spotting purposes. The most promising and versatile method from the literature is selected, modified, and demonstrated for industrial sized dies.

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“…This is an approximated method, where the accuracy is defined by the number of deformation modes used ( Struck et al, 2008 ). Großmann et al (2009) proposed an iterative method to adjust the shape of the forming tools to compensate its elastic deformation. The results show a significant influence of the tool deflection in the draw-in, mostly due to the distribution of the blank-holder force, which is higher on the die corners .…”

Section: Introductionmentioning

confidence: 99%