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Dortmund, Germany

Banabic D.,Technical University of Cluj Napoca | Sester M.,AutoForm Engineering GmbH
Materials and Manufacturing Processes | Year: 2012

This article is devoted to a comprehensive testing of the advanced materials models as implemented in the finite-element code. The influence of the numbers of the mechanical parameters on the accuracy of the sheet metal forming simulation has been studied for two materials (DC 04 steel grade and Ac121-T4 aluminum alloys). The results presented in the article prove the ability of the BBC2005 yield criterion to provide an accurate description of the anisotropic behavior for both steel and aluminium alloys. The performances of the model have been evaluated using the experimental data obtained from cross-die benchmark tests. The results demonstrate that for an accurate prediction of the sheet metal forming simulation it is crucial to take not only the uniaxial yield stresses and r-values into account but also the biaxial yield stress. © 2012 Copyright Taylor and Francis Group, LLC.

Kerausch M.,AutoForm Engineering GmbH
AIP Conference Proceedings | Year: 2011

Global competition is forcing the stamping industry to further increase quality, to shorten time-to-market and to reduce total cost. Continuous balancing between these classical time-cost-quality targets throughout the product development cycle is required to ensure future economical success. In today's industrial practice, die layout standards are typically assumed to implicitly ensure the balancing of company specific time-cost-quality targets. Although die layout standards are a very successful approach, there are two methodical disadvantages. First, the capabilities for tool design have to be continuously adapted to technological innovations; e.g. to take advantage of the full forming capability of new materials. Secondly, the great variety of die design aspects have to be reduced to a generic rule or guideline; e.g. binder shape, draw-in conditions or the use of drawbeads. Therefore, it is important to not overlook cost or quality opportunities when applying die design standards. This paper describes a systematic workflow with focus on minimizing material consumption. The starting point of the investigation is a full process plan for a typical structural part. All requirements are definedaccording to a predefined set of die design standards with industrial relevance are fulfilled. In a first step binder and addendum geometry is systematically checked for material saving potentials. In a second step, blank shape and draw-in are adjusted to meet thinning, wrinkling and springback targets for a minimum blank solution. Finally the identified die layout is validated with respect to production robustness versus splits, wrinkles and springback. For all three steps the applied methodology is based on finite element simulation combined with a stochastical variation of input variables. With the proposed workflow a well-balanced (time-cost-quality) production process assuring minimal material consumption can be achieved. © 2011 American Institute of Physics.

AutoForm Engineering GmbH | Date: 2012-04-24

A method for the characterization of a sheet metal forming product uses the correlation of material flow data to a priori calculated or measured data. It determines whether the product falls within the acceptable production limits in terms of quality, areas of potential defects and an approximation of the process parameters prevailing during its production. The characterization is performed in real-time during production, tool deployment or try-out. The method includes the steps of: providing physical dimensions of an actual sheet metal part; a feature extractor computing, from these physical dimensions, a measured material flow metric representative of the geometry of the part after the forming operation; and a matching unit determining, from reference data and the measured material flow metric, a matching forming operation data set whose associated simulated material flow metric most closely matches the measured material flow metric.

In a method for the numerical simulation of sheet-metal-forming processes, forming simulation parameters are visually displayed by:

AutoForm Engineering GmbH | Date: 2011-02-22

The invention concerns a method for the creation of addendums (

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