Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Contents
Introduction ......................................................................................................2
About This Series ...........................................................................................2
About This Book .............................................................................................2
Supporting Material ........................................................................................3
Product Design vs. Tool Design ..........................................................................4
Design Principles ............................................................................................4
Conflicting Demands.......................................................................................5
Tool Design - Analysis, Design and Optimization ..............................................7
Summary .......................................................................................................8
Metal Forming – An Overview.............................................................................9
Metals – Cradle To Grave................................................................................9
Sheet Metal.................................................................................................. 10
Drawing The Fuller Picture ............................................................................ 12
Critical Data - Material Properties .................................................................. 19
Its (Almost) All About Steel ........................................................................... 22
Numerical Analysis – An Introduction ................................................................ 24
Numerical Models ......................................................................................... 24
Important Terms .......................................................................................... 28
Summing Up ................................................................................................ 32
Finite Element Methods and Forming ................................................................ 33
A Retrospective ............................................................................................ 33
The Tool Designer and The Analyst ............................................................... 35
The Product Designer and The Analyst .......................................................... 37
Incremental Analysis - Numerical Aspects ...................................................... 38
Summary ..................................................................................................... 42
Putting It All Together: HyperForm ................................................................... 43
Process-Centric Modeling .............................................................................. 43
Forming Simulation – What and How............................................................. 44
Summary of Steps Involved .......................................................................... 49
Advanced Topics ............................................................................................. 51
Commercial Terms ....................................................................................... 51
Data Files – What Goes Where ...................................................................... 52
Glossary And References.................................................................................. 54
References................................................................................................... 59
Other Resources........................................................................................... 59
Sample Material Properties............................................................................ 59
1
Introduction CAE for Simulation of Metal Forming
Introduction
About This Series
To make the most of this series you should be an engineering student, in
your third or final year of Mechanical Engineering. You should have access
to licenses of HyperWorks, to the Altair website, and to an instructor who
can guide you through your chosen projects or assignments.
While a knowledge of FEA won’t hurt, it is not essential. As we will see, the
techniques used are at the very cutting edge of numerical analysis, but
these are so closely aligned with physically meaningful manufacturing
processes that an understanding of manufacturing technology is more than
enough to appreciate, to learn, and to bring this power to bear.
The various references cited in the book will probably be most useful after
you have worked through your project and are looking for ways to increase
the depth of the simulation techniques you have learned.
2
CAE for Simulation of Metal Forming Introduction
Supporting Material
Your instructor will have the Instructor’s Manual that accompanies these
volumes – it should certainly be made use of. Further reading and
references are indicated both in this book and in the Instructor’s Manual.
If you find the material interesting, you should also look up the HyperWorks
On-line Help System. The Altair website, www.altair.com, is also likely to be
of interest to you, both for an insight into the evolving technology and to
help you present your project better.
You have your way. I have my way. As for the right way, the correct way, and
the only way, it does not exist.
Friedrich Nietzsche
3
Product Design vs. Tool Design CAE for Simulation of Metal Forming
The words “tool design” are a little fuzzier. Even engineers who find the
phrase familiar are prone to misunderstand it.
Design Principles
Our interest lies not in the differences between tool design and product
design. Our approach is from an entirely different direction: we want to
study how the principles of product design can be applied to tool design.
This is not as radical as it may sound, since the tool itself is a product, of
course: it is the product that’s designed by the tool engineer or tool
designer. From our perspective, the tool that’s being designed is a product
like any other product, except that it may itself be used to manufacture
other products.
This means that the requirements that the tool-designer faces should be
similar to those faced by the (to use the term in its traditional meaning)
4
CAE for Simulation of Metal Forming Product Design vs. Tool Design
product designer. The familiar trinity – time – cost - quality - apply here too.
Tool designers too have to grapple with the problems of designing the tool
faster, making the tool itself cheaper, and improving the quality of the tool.
There are important differences of course, as we’ll shortly see, but from a
simulation perspective, tool designers stand to derive similar benefits from a
successful application of CAE1.
Apart from the fact that metal forming is well suited for CAE, it’s also a huge
business worldwide. For instance, in the automotive industry a typical
vehicle program averages US$ 500,000 per toolset. Automotive dies
worldwide are a 25 Billion USD business!
Conflicting Demands
Unlike the traditional product designer, the tool designer, like Damocles, has
to contend with a peculiar problem. Remember that time – cost – quality are
the most fundamental objectives of any design. Unfortunately for the tool-
designer, the design of the tool has an impact not just on the cost of the
tool itself, but of the products that are manufactured using this tool. This is
because product-marketing companies recover the price of the tool from the
price of the products. The mathematics is not always simple. The direct
contribution of the tool cost to the cost of each product is easy: it’s the cost
of the tool divided by the number of products manufactured using this tool.
1
Short for Computer Aided Engineering, usually taken to mean Finite Element
Methods.
5
Product Design vs. Tool Design CAE for Simulation of Metal Forming
But there are several indirect costs that are harder to account for. For
instance, since the tool is bound to wear, the denominator in the previous
equation depends on the design, which determines the tool life. Further, the
amount of raw material that’s required for each product also depends on the
efficiency of the tool itself. If there’s a high wastage, the contribution of
material-cost to the cost of the final product will rise.
Obviously since both the designers – tool and product – are working towards
the same goal, this is not a happy situation at all.
Analysis of a design is easier than the design itself. An analyst starts with a
well-defined problem and searches for the solution. In contrast the designer
is faced with a problem that is rarely clearly defined, and that almost always
has more than one acceptable solution.
If CAE is used to verify a design, it’s often too late in the design cycle to
implement any changes that the analyst recommends, unless the analyst
predicts failure. Wouldn’t it be great if the designer had a method that
7
Product Design vs. Tool Design CAE for Simulation of Metal Forming
could help suggest designs that are least likely to get rejected by
subsequent CAE? In other words, we would like to put forward our definition
of a “satisfactory” design, and have the software suggest to us a tool-design
that is most likely to pass the subsequent analyst’s verification.
Summary
This discussion, then, leads us to a few unarguable points:
• CAE is used more widely for product design than tool design
We’ll spend the rest of this book investigating how to convert these wishes
to fact.
If I had eight hours to chop down a tree, I'd spend six hours sharpening my
ax.
Abraham Lincoln
8
CAE for Simulation of Metal Forming Metal Forming – An Overview
Since there are several books that do the job admirably, we won’t attempt
to reproduce the material here. Our goal in this chapter is to summarize the
metalworking processes that are relevant to our simulation goal.
When tool-designers talk of the raw material, then, they mean the physical
form in which it is received for further processing.
2
Excluding the Lanthanides and Actinides
3
Aluminum is widely used in the aircraft industry, where it is being seriously
challenged by composites.
9
Metal Forming – An Overview CAE for Simulation of Metal Forming
Metalworking starts where the furnace leaves off. Steel is either cast in
ingots and rolled to a more manageable size, or continuous casting delivers
billets or blooms directly from the furnace. Rolling, apart from reducing the
size, also work-hardens the material. Properties of the metal, of course, can
be manipulated by one or more of several heat-treatment processes –
annealing, quenching, tempering, and so on – as well as by surface
treatment processes such as nitriding or carborising. Aluminum is frequently
extruded, unlike steel. Both metals can be cast, using either gravity die-
casting or pressure die-casting, following which machining provides the
necessary finish and dimensional control. From a tool-design perspective, all
the operations above involve the design of a tool – whether it’s the cutting
tool used for machining, the die for casting, or the rolls for rolling.
Sheet Metal
Sheet metal is not only inexpensive and lightweight, it can be worked quite
easily. As a result, it’s used pretty much everywhere – from computer
cabinets to roofing sheets. Sheet metal is sometimes specified by its gauge4,
which is not always easy to interpret since the gauge refers to the weight of
the sheet, not it’s thickness. As a result, a sheet of one alloy can have a
different thickness than the same gauge sheet of another alloy.
Sheets are produced by either hot or cold rolling. The latter is more difficult,
but produces stronger steel since it’s work-hardened. Cold-rolled steel is
usually annealed to improve its ductility.
4
Sometimes spelt gage
10
CAE for Simulation of Metal Forming Metal Forming – An Overview
point of view, drawing involves a flow of the material while the others do
not.
5
Studies do show variation within strips, but these are often within the acceptable
range.
11
Metal Forming – An Overview CAE for Simulation of Metal Forming
This complication, of course, is the main reason the designer turns to them
– because it allows you to tailor the properties of the blank by choosing
which part of the blank should have which properties.
In any case, the tool designer’s goal is to design both the tool and the
process so as to ensure that after the metalworking is done, the finished
product meets specifications. Specifications themselves can vary widely. In
some cases, notably the outer panels of car bodies, the finish must be good
enough that the product need be subjected to no more work, except
painting. In other cases, dimensional accuracy is critical. Some product
designers demand a thickness that’s close to uniform. The last is often
specified as a permissible thinning percentage.
And in addition to meeting these specifications, the tool designer must also
ensure that the tool-life is adequate, the tool cost is kept as low as possible,
and the process requirements are within the capability of the available press
shops! If, for instance, the tool designer chooses a blank that is too thick,
the press itself may get damaged.
It’s when the deformation is along a more complex path that CAE is
indispensable.
12
CAE for Simulation of Metal Forming Metal Forming – An Overview
It’s interesting to note that Bramah was principally a lock-maker: the fact
that locks require high-precision components motivated him to develop tools
to assist in the manufacturing process.
Presses are also categorized as single acting, double acting or triple acting.
A double acting die, for instance, has two slides. In addition to the ram the
ejector also moves.
13
Metal Forming – An Overview CAE for Simulation of Metal Forming
Of the several questions the tool designer has to answer, one of the most
vexing is how many stages are required to form the component.
Components that have a low draw-depth (relative to the major transverse
dimension – for example, the radius of a cup) can be formed in one stage,
while deeper draw depths require a multi-stage process. That is, the blank is
worked in different dies to reach the final shape.
The goal is to reduce the number of stages as far as possible, since both
cost and time-required are directly proportional to the number of stages. For
instance, the component shown above can be completed in a single stage if
a double-acting press is used, even if the depth demands two stages with a
single-acting press. Sometimes a transfer die is used to automatically move
the component from one stage to the next, reducing material handling costs.
Regardless of the number of stages, the cost of the press and dies often
means that OEMs adopt a hub-and-spoke approach. In this approach, a
single press-shop feeds several assembly shops. If the gap between the time
of manufacture and the time of assembly is large, the component may
deform under its own weight. Remember that we are dealing with sheet-
metal which is thin, and is often quite long and wide, as with a car bonnet.
This is a product-design problem, not something the die-designers have to
worry about.
14
CAE for Simulation of Metal Forming Metal Forming – An Overview
But components like these pose another problem for the die-designer. If the
formed component is thin enough that it will sag under its own weight, the
blank will be, if anything, even more flexible. This means that when the
blank is placed on the binder, the designer needs to account for the gravity-
related deformation that takes place before the punch makes contact with
the blank. This gravity-effect can significantly change the behavior of the
tool, so should not be ignored6.
In some cases the binder is curved, in which case the bending of the blank
when the binder is clamped shut, before the punch contacts the blank, is
called binderwrap. Like the gravity-effect, this too can significantly change
the behavior of the tool.
Hydroforming
Hydroforming is a technique that is less widespread, but not only is it often
commercially viable, it is sometimes essential. It is often used to form tubes,
with operations like bending, flaring, beading and bulging.
The press, of course, is hydraulic, but the critical difference with the more
“traditional” hydraulic press is the method of application of force on the
blank. For tube hydroforming, for instance, fluid at a high pressure is forced
into the tube. This pressure makes it deform. Apart from the fact that a
liquid can enter areas that a solid punch or die cannot, the advantage is that
the pressure is uniform all across the component7.
Hydroforming is slower since the fluid pressure has to be ramped up, and
hydroforming presses are more expensive to construct. The effect they have
on the strength of the finished component is sometimes so useful that the
increased cost and slower production rate is acceptable as illustrated by the
table8, in which the “baseline” costs are for a “traditional” forming press:
6
See CAE And Design Optimization – Basics for methods used to stiffen sheet-metal
components after assembly.
7
As Pascal’s Law tells us it should.
8
See Lightweight SUV Frame – Design Development, May 2003, on the Altair
website.
15
Metal Forming – An Overview CAE for Simulation of Metal Forming
Baseline Hydroformed
Process Parameters
Now that we are familiar with the general machine and tool related aspects,
let’s take a closer look at the process of forming itself.
We know that the tool-designer’s job starts from where the product-designer
left off. Decisions or choices made by the part-designer will obviously have a
significant impact on the tool-designer, of course, but there are some
aspects that can be decided entirely by the tool designer. These aspects,
specific to the manufacturing process, are what we call the process
parameters.
From what we have studied so far, we know that the tool designer’s goals
are
Sheet metal behavior during actual press production is difficult to define and
measure. Production involves the interaction of many variables, which
means that the impact of one variable on the process outcome can be
difficult to even observe, let alone measure9!
9
See CAE and Design Optimization – Advanced for a discussion on the Design Of
Experiments (DOE) to study such affects.
10
Siekirk,J., Process Variable Effects on Sheet Metal Quality, Journal of Applied
Metalworking, American Society for Metals, July 1986
17
Metal Forming – An Overview CAE for Simulation of Metal Forming
• lubrication
• binder force
This helps reduce the problem to a more tractable level, and allows
remarkably accurate simulation of the complex process, as we will see in the
subsequent chapters.
Before we go on, though, it’s important to note that in some cases the
product design specifies the material to be used, while on other cases the
tool designer has some room to maneuver. This is a mixed blessing since
not all parameters of steel improve in tandem. For instance, as hardness
rises toughness (or shock resistance) usually falls.
Either way, the tool designer needs to estimate the formability of the
material – that is, how is it likely to flow within the die under a given set of
process parameters.
Lubricants
Of all the process parameters, lubrication is one that merits a special
discussion. In the first place, friction is poorly understood even today. The
“laws” of frictions should really be called “theories”. In the second place, the
lubricants are not easily quantified.
In the context of sheet metal forming, lubricants have multiple origins and
multiple effects. In several cases, a coating is applied to the sheet at the
steel mill to inhibit rusting. This often remains on the sheet, and can be used
18
CAE for Simulation of Metal Forming Metal Forming – An Overview
to aid forming. In other cases, a lubricant is applied in the press shop after
the blank has been cut from the coil or sheet. Alternately, a lubricant may
be applied selectively to assist flow in critical areas of the die.
The yield stress and tensile strength of the material are easily obtained from
the stress-strain curve.
If the stress exceeds the tensile limit, the material will fracture, which means
our sheet-metal will tear. Between the yield point and fracture, the material
undergoes plastic deformation. There are several theories of plasticity, but
one has been found to work well for the simulation of sheet-metal forming –
power-law hardening. Under this theory, the stress strain dependence is of
the form
σ = K ∗ (ε 0 + ε ) n
n is given by
19
Metal Forming – An Overview CAE for Simulation of Metal Forming
n=
(d [ln σ T ])
d [ln ε ]
σ u ∗ en
K=
nn
where σu is the tensile strength, e is 2.718 (the base for natural logarithms)
and n is the strain-hardening exponent.
1
σ n
ε 0 = y
K
to calculate ε0.
σ = kε n • ε& m
In this case, we calculate m using the equation
m=
(d [ln σ T ])
d [ln ε& ]
dε
where ε& is the strain rate, , and σT is the true stress
dt
(Recall the difference between engineering stress / strain and true stress /
strain: the former uses the original dimension while the latter uses the
instantaneous dimension.).
20
CAE for Simulation of Metal Forming Metal Forming – An Overview
r=
(r o +2r45 + r90 )
4
∆r =
(r o −2r45 + r90 )
4
• yield stress – for example, 390 MPa for a High Strength Steel
11
Named for Lankford W.T. Published with Snyder SC and Bausher JA, Trans. ASM
1950; 42:1197
21
Metal Forming – An Overview CAE for Simulation of Metal Forming
All this is from a theoretical perspective, but it doesn’t tell the complete
story. The tool-designer has to actually get these values!
One option is to measure it, while the other – and more reasonable – option
is to get it from the supplier of the steel and verify it by testing a sample. It
is important to pay attention to quantifiable parameters, as opposed to
descriptive terms. For example, the terms “stronger” and “harder” are not as
useful as the yield-stress and Rockwell hardness respectively.
12
AZoM.com: http://www.azom.com/details.asp?ArticleID=534
22
CAE for Simulation of Metal Forming Metal Forming – An Overview
through rationalization of car body structures and the use of lighter gauge,
higher strength steels.
23
Numerical Analysis – An Introduction CAE for Simulation of Metal Forming
Read this chapter and the next with this in mind. In this chapter, we outline
the basics of FEA as relevant to our application – the modeling and
simulation of sheet-metal dies, punches, and the blank. We will complete
our study of the FE method in the next chapter13.
Numerical Models
As a designer, you need to anticipate the behavior of the product you’re
designing. You will need to guess at the conditions it is likely to be exposed
to, and then to predict how it will respond to these conditions.
In some situations, the response of the body to stimuli is linear. That is,
there is a linear correlation between input and output. Such a model is,
obviously, called a linear problem. Other situations are non-linear because
there’s no linear dependence between stimulus and response.
It’s important to remember that the product you’re analyzing does not know
whether it is “linear” or not. You, as the analyst, can choose to model it as
linear or as non-linear, depending on which is more likely to give you useful
results. Since we are designers, not mathematicians, we are not interested
in results that are “exactly correct”. We are willing to settle for
“approximately correct” provided we get the results in time and at a cost we
can afford.
As you know from your courses on Linear Algebra and Differential Equations,
linear equations are far easier to solve than non-linear equations. Therefore,
13
A Designer’s Guide to Finite Element Analysis, a part of this series, covers FEA in
more detail, and from a more general perspective.
24
CAE for Simulation of Metal Forming Numerical Analysis – An Introduction
Non-linear models are of several types – the materials used, the geometry
involved, or conditions on the boundary can cause the “non-linear” nature.
Examples of material non-linearity are plastic deformation, melting and
solidification – the stiffness of the body changes as the material properties
change. Other problems involve geometric non-linearities - the stiffness
changes as the body deforms even if the material’s properties do not change
– take for example the reduced rigidity of a plastic bottle as it is crushed. An
example of boundary non-linearities is contact, because the stiffness of the
part or assembly changes as sections come into contact with each other.
What is FEA
Finite Element Analysis (FEA) simulates a physical part or assembly’s
behavior by dividing the geometry of the part into a number of elements of
standard shapes, applying loads and constraints, then calculating variables
of interest – deflections, stresses, temperatures, pressures, etc. The
behavior of an individual element is usually described by a relatively simple
set of equations. Just as the set of elements would be joined together to
build the whole structure, the equations describing the behaviors of the
individual elements are joined into a set of equations that describe the
behavior of the whole structure.
Elements themselves are defined by specifying the nodes, which are the
vertices of the element. Just as 4 corners define a rectangle, the nodes
define the shape of an element.
14
A more complete discussion is presented in A Designer’s Guide To Finite Element
Analysis.
25
Numerical Analysis – An Introduction CAE for Simulation of Metal Forming
When you choose an element to represent a part of the product, you are
also specifying the parameters that define the behavior across the element.
For instance, in a stress analysis, if you know the 6 components of
deformation15 at any point, you can calculate the strain from this by taking
the first spatial derivative. And once you know the strain, you can use the
material properties to calculate the stress. For the Finite Element Method,
every node has these parameters associated with it, just as in a truss-
structure every member has forces associated with its end-points. From the
values at the nodes, you can interpolate for the values between the nodes.
A Finite Element program takes the elements you have defined, lists the
equations for each unknown value, puts them together as a matrix equation,
then solves all these for the values of the unknown parameters.
[K ]{u} = { f }
Since it’s analogous to the equations of spring-deflection, K is often called
the Stiffness Matrix, u is called the deformation vector, and f is called the
load vector. K is a square matrix, with one row (and column) for each
15
The 6 components are the translations along the 3 axes, and rotations about the 3
axes
16
A high stress means a high strain, from Hooke’s Law. Strain is the first derivative
of deformation. Hence a high stress area is one where the deformation has a high
derivative. And this, of course, means the rate-of-change of deformation is high in
areas of high stress.
26
CAE for Simulation of Metal Forming Numerical Analysis – An Introduction
unknown variable in the problem-definition. If, for instance, you have used
100 nodes in your model, and each node has 6 unknowns17, your stiffness
matrix would be 600 x 600. u and f are each column-matrices. In our
example, each has 1 column and 600 rows.
du
u& = v =
dt
ut + ∆t − ut
v=
∆t
While the approach is logical and simple, there are some subtleties to this.
17
The 6 components of deformation are the translations along 3 axes and the
rotations about the 3 axes
27
Numerical Analysis – An Introduction CAE for Simulation of Metal Forming
ut + ∆t = vt • ∆t + ut
Since we have ut and ut+∆t, can we estimate vt+∆t? If we can, we can apply
the equation above to estimate ut+∆t. And by stepping forward in time, we
can calculate the solution at any required instant of time. But estimating the
value of vt+∆t is ambiguous. As shown in the figure, it is not clear to us
whether the tangent (which is what v is) that we can calculate using the
equation
u t + ∆t − u t
∆t
Without going into the detail, we will simply note that the choice leads to
different finite difference methods – the backward difference method, the
forward difference method, the central difference method, and so on.
&& .
Similar logic is applied to the calculation of the acceleration, u
Important Terms
As with any technical subject, Numerical Analysis has a wide range of terms
that have very specific meanings given the context. Here, we’ll review those
that are particularly relevant to our task.
Elements
An element is a shape for which the Finite Element program can write out
the equations relating the unknown and known quantities. An element is
defined by its nodes – the unknowns at each node are called the degrees of
freedom.
Shapes that are accepted in most finite element programs are triangles,
quadrilaterals, lines, tetrahedra, pentahedra and hexahedra.
The sizes of and the number of elements usually have a bearing on the
accuracy of the solution. As problems become more complex (advancing in
complexity from linear-statics to nonlinear-dynamics), the requirements on
shapes and sizes of elements become increasingly stringent. These
28
CAE for Simulation of Metal Forming Numerical Analysis – An Introduction
In most analyses, the more the number of elements, the better the results.
However, the computer time and disk-space required to solve the equations
also goes up. Most analysts have to settle for a quality of results that they
can afford, given the available computer resources.
Element Types
Choosing the element type is an important part of any Finite Element
analysis. Elements are categorized based on their shape or topology, the
number of nodes needed to define them, and the mechanics or behavior
they represent.
Element types are usually solver dependent – they vary based on the solver
used. The elements listed below are specific to OptiStruct, but are available
in almost every commercially available analysis package.
29
Numerical Analysis – An Introduction CAE for Simulation of Metal Forming
Geometry Preparation
While it is possible to build a model directly using elements and nodes, this
is not often done today. The geometry that defines the area to be analyzed
(also called the “domain”) is usually created first using a CAD program, and
elements are created to encompass that boundary or represent the volume.
CAD designers create models for manufacture. As many details are included
as possible. For a numerical analysis, we often choose to ignore aspects that
we think will not significantly affect the solution. For instance, a single hole
of 1 mm radius in a plate that is 2 meters wide can probably be ignored
safely when calculating the deformation of the plate.
Therefore the first task that most analysts are faced with is that of preparing
the geometry for analysis. This involves tasks like removal of features,
extraction of mid-surfaces, extrapolation of surfaces, etc.
Further, the CAD world has an abundance of data exchange formats, since
most CAD applications use proprietary data storage formats. A transfer of
data from the CAD package to the FE preprocessor sometimes results in a
loss of accuracy – gaps are introduced during the import process, for
example. Also, CAD assembly models are sometimes made up of parts that
were created in different CAD applications.
30
CAE for Simulation of Metal Forming Numerical Analysis – An Introduction
Mesh Creation
Once the geometry is more or less ready for discretization, you then start to
subdivide the geometry into elements or grid points. The collection of
elements is usually referred to as a mesh. Meshes that consist of triangular
or quadrilateral elements can often be generated automatically, while
tetrahedral or hexahedral meshes usually require considerable manual
intervention.
Mesh Editing
Once a mesh has been created, the analyst checks if it meets the
specifications – several measures of quality are checked, depending on the
analysis requirements. Usually, some editing of the mesh is required.
Depending on the complexity of the mesh, this can be done either semi-
automatically or manually.
Once this is done, the data is turned over to the solution program for the
next phase – solving. Data is often written out in the form of a text file,
which is referred to as a deck. Each line of text in the deck is commonly
referred to as a card. A card image is the format followed by the analysis
program to interpret the text on the line.
Solving
The model created in the earlier steps is now taken up for solution – the
computer program reads the data, calculates matrix entries, solves the
matrix equations and writes data out for interpretation.
31
Numerical Analysis – An Introduction CAE for Simulation of Metal Forming
This task is CPU-intensive, and is often called processing18. Most of the time,
very little interaction from the user is required. In some cases, the analyst
periodically monitors results to check that they are indeed on the right track.
If the solution seems to be evolving in an unexpected direction, the analyst
can stop the solver and modify the model, thereby saving valuable time.
Post-Processing
After the program has evaluated the results, the analyst examines and
interprets the data – looking for errors or improvements in design.
As with pre-processing, this calls for substantial interaction from the analyst.
Summing Up
This last aspect is comforting, since model preparation usually takes up to
80% of many analysis tasks. Unfortunately for us, there are no free lunches:
our challenge lies in the complexity of the solution. Remember that the
simulation of sheet metal forming is not only a transient problem, it involves
all three types of non-linearities – material, geometric and boundary. In the
next chapter we’ll look at the strictures imposed on us by methods used by
today’s analysis techniques, and how to deal with them effectively.
18
Hence the term pre-processing for the preceding steps, and post-processing for
the subsequent steps.
32
CAE for Simulation of Metal Forming Finite Element Methods And Forming
First, we have seen that a relatively small subset of the forming process
parameters is adequate – this simplifies the first part. Next, the finite
element method’s strength comes from its generality. It is applicable to a
wide range of problems. Our focus, however, is very narrow – this helps cut
out a lot of the complexity in the second part of the package.
A Retrospective
Since metal forming is a lot older than computers or the Finite Element
method, it’s logical to ask how designers managed before the advent of
numerical simulation. That’s a little like asking how people handled
transportation before the advent of the automobile: they managed, but it
wasn’t elegant and it wasn’t efficient.
Arguments between designers and engineers were all too frequent. “The
engineers may say the design is too difficult to execute; it's going to add
weight or cost. They ask if they can move something an inch.” said
automotive legend Bob Lutz in an interview19, “We say, No, the whole
vehicle concept depends on the integrity of the design. Try to work with it,
without watering it down."
Die design was based on heuristics to estimate the die-face. This was
followed by tryout, which meant the die and punch had to be manufactured
and experimented with. The experimentation almost always led to
considerable rework. Worse, the time taken to arrive at an acceptable
design and suitable process parameters could rarely be forecast.
19
See the Corporate Design Foundation - http://www.cdf.org/issue_journal/6.html
33
Finite Element Methods And Forming CAE for Simulation of Metal Forming
Estimation of the blank shape and size was another source of concern. In
the first place, procedures to estimate the blank size were reliable only for
single-stage draws. Further, such estimates were less accurate than desired
(remember that wasted material adds to material cost) since graphical
methods were used in the main. These methods are roughly similar to the
development-of-surfaces methods covered in basic engineering drawing
courses. They take into account the shape of the object, but do not allow for
the flow of the material. This explains why these methods are not suitable
for deep-drawing: as the flow of material increases, the method’s accuracy
falls.
Tool and Die making was, in the good old days, largely an art. Simulation
has helped turn it into a science. The pressure exerted by consumer demand
has helped drive the push towards more reliable and accurate forms of
design. The changes in the shape of cars is an excellent example – in the
interview cited above, Bob Lutz explains
“In the teens, cars looked like horseless carriages. In the late '20s
and '30s, they became very boxy, and in the mid-'30s, they
became boxes with rounded corners. Toward the end of the '30s,
streamlining came in. In the '50s, we got into the "pontoon" shape
where the fenders disappeared. Then we moved more and more
toward pure aerodynamic shapes.”
But history is not all bunk. Two methods that tool designers have long relied
on are instructive: circle-grid analysis and the Forming Limit Diagram20
(FLD).
20
Also called the Keeler-Goodwin diagram.
34
CAE for Simulation of Metal Forming Finite Element Methods And Forming
A high stretch of the circle indicates forming problems, but we can do even
better than this. Each material has a particular failure-strain ratio under a
given set of process parameters – the limit depends mainly on the sheet
thickness, the strain-hardening exponent, and so on. That is, if the ratio of
major and minor strains exceeds this value – the forming limit - the metal
will tear.
To use this measure of failure, we first plot the forming limit curve on a
graph, with the minor-strain on the x-axis and the major-strain on the y-
axis. Now using the values measured from the circle-grid analysis, we check
whether the various points on the blank are under or over the forming limit
curve. If all circles are under the FLD, the forming process is safe.
Note that this method does not remove the need to tryout. Instead, it
improves the utility of the tryout by providing a quantitative measure of the
results of the tryout. Remember that the FLC itself has to be determined
experimentally. If the specimen has local defects (tearing, thinning, etc.),
the FLC is obtained by measuring the major and minor strains in areas that
have defects and neighboring areas that are defect free. This boundary is
plotted as a solid line on the FLD.
What this means is that the analyst today cannot dispense with the tool-
designer. The tool-design experience and insight guides the combinations of
parameters to simulate. In the absence of such guidance, the analyst is
faced with literally infinite combinations! Optimization techniques can help
address this issue, but these are beyond the scope of our discussion21.
21
See CAE and Design Optimization - Advanced
35
Finite Element Methods And Forming CAE for Simulation of Metal Forming
Consider, for example, the choice of the addendum. As shown in the figure
(the exploded view is shown on the right), this is the region between the
undeformed blank and the finished component – it’s trimmed off after the
forming is complete.
The product designer specifies the final component, which is what you get
after trimming. Assuming the blank is a flat sheet (as it will be for the first
stage of any drawing operation), what should the shape of the addendum
be? Obviously this is a decision related to the die-face itself. One way to
construct the addendum is to use blends, fillets and other CAD operations to
fill the area between the trim-line and the flat sheet. However, the
addendum design itself can critically impact the flow of material. Proper
addendum design ensures uniform panel stretch, since it affects the balance
of material movement.
In the first figure on the left, since the section A is the same as section B,
the effect of blank holder pressure is the same on both. But in the second
figure, the two sections are unequal. If the same blank holder force is used,
side A will wrinkle or the other side will tear.
Controlling blank holder pressure locally is not always possible. To deal with
the situation shown, the designer has to slow down the flow of material on
one side – this is done using a draw bead. Just as a speed-bump on a road
forces vehicles to slow down, the bead retards flow of material in the blank.
The designer has to specify the location of the bead, its radius and height,
36
CAE for Simulation of Metal Forming Finite Element Methods And Forming
after which the analyst can check the performance of the die in a given
press.
Using Finite Element models to carry out a non-linear finite element analysis
allows a detailed simulation of the draw process. This approach is called
incremental analysis, since the analysis program steps-forward in small
increments of time, and is ideal for the tool-designer.
37
Finite Element Methods And Forming CAE for Simulation of Metal Forming
Events of such a short duration are inherently hard to simulate – both the
numerical methods and the theories of mechanics are not as general as
desired. As a result, several FE modeling decisions are governed by a
combination of theory and practice.
In this section, we will review the modeling approaches used specifically for
the simulation of sheet-metal forming. These are not applicable to FE
analysis in more general circumstances. This has one very useful side-effect:
the availability of these guidelines makes it easier for the analyst to simulate
forming even without an in-depth understanding of the mechanics and the
mathematics!
Choice of Elements
Finite element modeling involves two important choices at the mesh-
preparation stage. The first is the type of elements to use, and the second is
the size of the elements. Since the blank is a sheet, shell or plate elements
are appropriate. Automatic mesh-generation for shell elements is quite
advanced, which this makes this stage quite easy.
The punch and die must also be modeled, of course. But our interest lies in
the force they exert on the blank, not in the deformation they themselves
undergo. Accordingly, we can model the punch or die using shells too and
22
The velocity of the ram of a mechanical press is of the order of meters / second,
while the draw depth is of the order of millimeters or centimeters.
38
CAE for Simulation of Metal Forming Finite Element Methods And Forming
then tell the analysis program that they are to be treated as infinitely rigid
elements. This avoids one of the more time consuming aspects of general FE
modeling – the construction of hexahedral elements.
In either case one guideline is to ensure that there are no fewer than 6
elements for each quadrant of a circular arc.
• explicit methods are conditionally stable – that is, the time limit
must not exceed a specific value. As a result, explicit methods
require more time steps than implicit methods for the simulation
to reach the same elapsed-time.
Ls
∆te =
c
39
Finite Element Methods And Forming CAE for Simulation of Metal Forming
We can calculate c for any material using the Elasticity Modulus E, density ρ
and Poisson’s Ration ν and the formula
E
c=
ρ (1 − υ 2 )
For a given mesh, the time step is limited by the smallest element in the
mesh. In other words, the finer the mesh, the smaller the time step. A finer
mesh size will give more accurate results, but the time for analysis will go up
not just because the number of elements has increased but because the
number of steps will also rise – because the time step size reduces as the
element size reduces.
This doesn’t seem very helpful, in itself, particularly when we remember that
forming involves large deformation. That is, the element shape itself will
change considerably as the analysis progresses.
One option is to start with elements that are small enough that the
deformation will not change the element’s shape appreciably, but this is
hard to decide before carrying out the analysis. And the analysis cannot be
carried out until the elements are chosen. The answer to this impasse lies in
the use of adaptive refinement.
Adaptive Refinement
One remarkable facet of the finite element method is that the error in the
analysis can be estimated from the approximate solution itself. Programmers
can use this characteristic to adapt the mesh based on the estimated error.
This is of enormous help, since it frees the analyst from the burden of
choosing the “right” element size. You can specify a reasonable size and let
the program itself correct the mesh as the analysis proceeds.
There are several different ways in which the mesh can adapt – the
elements can be reduced in size (h-adaptive), the order of interpolation can
23
The characteristic length can be calculated in several ways, as explained in the on-
line documentation. One option is to use the altitude of the element as the
characteristic length.
40
CAE for Simulation of Metal Forming Finite Element Methods And Forming
If the program uses adaptive refinement, it must also check and change the
time-step size as the analysis proceeds, of course, using the CFL criterion as
a limit. At each time step, the program checks the maximum time step
permissible, as decided by the smallest element in the mesh.
The smallest element, then, works as a bottleneck – it limits the time step
size. What if there are only a few elements that are so small? Mass-scaling
provides a way out.
Energy Balance
Non-linear analysis, particularly when it involves friction (which is a non-
conservative force) is more of an engineering tool than a numerical science.
In a precise calculation, energy is always conserved. In many explicit
analyses, we tolerate some imbalance in energy in return for a reduced
analysis time. Depending on the problem, some level of loss of energy from
the system is usually tolerated. The actual tolerable level depends on how
much time and effort you can afford, but 10% is often deemed acceptable.
Mass Scaling
In a similar vein, we are often willing to artificially boost the mass of
elements in order to increase the time step size. The justification for using it
lies in the fact that we may be unwilling to let a small section of the model
penalize the rest. Accordingly, we may tell the program to increase the
density of elements by a particular factor, provided the mass of the whole
model does not rise by more than (for instance) 10%.
Mass scaling helps since the mass of the element appears in the numerator
of the CFL criterion, so an increase in mass increases the time step. Of
course, this increase in mass is physically meaningless, and does degrade
the accuracy of the analysis.
Contact
As the punch approaches the die, the program must check whether or not
contact has taken place. It must then track the deformation of the blank and
the movement of the punch, using the die face as the limit. Depending on
the lubricant used, the coefficient of friction determines the friction forces
and consequent energy loss. Implementing this search-and-solve process is
computationally expensive, and difficult.
41
Finite Element Methods And Forming CAE for Simulation of Metal Forming
Contact algorithms today are much more robust than they were even a few
years ago, and by and large are fairly reliable.
Summary
Simulation of forming requires powerful computing resources, a working
knowledge of the finite element method, access to process and material
data, and an excellent understanding of the manufacturing processes
themselves.
Implicit in all this, of course, is the fact that the simulation is only as good as
the data: if the material data is unreliable or if the process parameters are
incorrectly specified, it is foolish to expect the results to be realistic!
Several other aspects like design of the die face, optimization of the die, and
estimation of the affect of residual stresses on the strength of the part are
also possible using current simulation techniques, but are beyond the scope
of this book.
42
CAE for Simulation of Metal Forming Putting It All Together - HyperForm
This is not because our earlier discussions were off track: it is indeed true
that simulation of metal-forming is indeed difficult to conduct and it’s all too
easy to generate wrong results. It is HyperForm’s modeling approach,
coupled with the relatively focused demands of the task, that make it so
easy to get going. In this chapter we
Process-Centric Modeling
Many design-and-modeling tools are hard to learn because they provide a
combination of depth and breadth. HyperMesh and HyperView, for instance,
can be (and are!) used for an extremely wide variety of very demanding
applications.
Our goal is much less general: we are restricting our attention to one
specific type of product (sheet-metal) and one specific process (forming).
Accordingly, we do not need a modeling application that can be used for
general requirements; we need an application that talks the language of
metal forming. Further, we expect the application to be used either by tool
designers or by product designers. As we have seen, there are some
common approaches and some differences between the approaches that
tool and product designers take.
But don’t let this ease of use lull you into feeling secure. While it’s easy to
use HyperForm, and results can be remarkable accurate, it is also extremely
easy to generate results that are off-track. After getting comfortable with
HyperForm, in fact, it’s a good idea to go back and review the earlier
chapters to recall the areas that are absolutely critical!
An extract from a recent article24 serves well to drive home the limitations
and strengths of simulation, and to stress the importance of design know-
how:
There is (an) issue to resolve regarding who is responsible for the die
design. If the (product designers) uses Die Face Engineering to create a
full tooling model they can examine formability of their own designs.
However the simulation results will only be valid for this die face – if the
product is then sent to an external tooling engineer there is no guarantee
that the same process will be adopted. On the other hand, is the (product
designers) issue their tooling process to the tooling engineer they will
potentially be taking responsibility for the tool design, with major
implications if the process does not, after all, make an acceptable part.
24
Dutton, T., Review of Sheet Metal Forming and Simulation – Progress to Date,
Future Developments, 8th International LS-Dyna User’s Conference
44
CAE for Simulation of Metal Forming Putting It All Together - HyperForm
product designer’s requirements will be met if the simulation shows that the
product is easy to manufacture in a single stage.
Such a product, it is reasonable to expect, will pose few problems for the
tool designer later in the design cycle.
The need of the hour, obviously, is to get an estimate on the size of the
blank.
Going one step further, the blank itself is cut from a coil or strip of sheet
metal. The problem is to choose an arrangement of blanks on a given width
of coil so as to minimize wasted material. The two products shown clearly
show that one necessitates a higher wastage than the other.
In any case, HyperForm starts where CAD leaves off – data from a CAD
package is essential to get started with simulation. The product itself is
45
Putting It All Together - HyperForm CAE for Simulation of Metal Forming
essential, and depending on the role played by the analyst, additional data
may be required too, as we will see.
One-Step Simulation
The only data we require is the CAD model of the product itself. If the
component has holes, we can investigate both alternatives – one where the
holes are made prior to forming, and the other where the holes are made
after forming. To simulate the latter, we just fill the holes up before carrying
out the analyses.
The component is first checked for undercuts – that is, whether it can be
ejected properly from the die. To check this, we need to set the draw
direction (the axis of relative travel of the punch and die). The convention in
HyperForm is that the tool travels along the “Z” axis. If an undercut is
detected, in some cases it can be fixed by altering the orientation of the
product relative to the draw direction. This is called tipping.
Once the product has been oriented correctly, we generate a finite element
mesh. The elements only need to be fine enough to satisfy the requirements
of the “inverse” method (described earlier) that’s used to estimate the blank
shape. Automatic mesh generation is usually adequate.
Then we specify the material used and the thickness of the sheet. This can
be selected from a library of data that comes with HyperForm or, if accurate
data is available, can be entered explicitly.
That’s it – the model is ready for analysis. Given this data, HyperForm
calculates the blank shape and the FLD diagram.
The latter serves to check whether the product is likely to wrinkle, tear, or
exceed the maximum permissible variation in thickness.
The approach above is reliable for parts that can be formed using a single
stage, and that do not require post-forming trimming. If the part requires
trimming, the flange that is to be trimmed off can be added to the mesh
before simulation, of course. This method requires a little more caution,
since the size of the flange can affect the formability. It does offer the
advantage that the impact of drawbeads can be investigated: you can run
the simulation with and without drawbeads to determine whether t his
impacts the results.
46
CAE for Simulation of Metal Forming Putting It All Together - HyperForm
Since the analysis is not very detailed, the normal approach is to use
analytical drawbeads. That is, instead of actually modeling the bead itself, a
line or curve that represents the center of the draw bead is specified, and
the analysis carried out.
Incremental Analysis
Setting up a problem for a more detailed analysis – using the incremental
solver instead of the one-step solver – is similar, except that there are a few
more parts to be modeled, and a few more process parameters. Once you
understand the principle, the same approach can be followed regardless of
how complex the forming sequence is. So we’ll first segregate the processes,
then look at the steps.
47
Putting It All Together - HyperForm CAE for Simulation of Metal Forming
Data Required
HyperForm makes it easy for us to setup the analysis, but the reliability of
the results depends strongly on the quality of the data. Data required is of 4
principal types:
Material data is best obtained either from the steel-suppliers, or from actual
tests. The geometry of the blank, punch and die are best obtained as CAD
data from the die designer – remember that the addendum, for example,
can significantly affect the performance. It’s up to the analyst to ensure that
the mesh is fine enough, as discussed earlier.
48
CAE for Simulation of Metal Forming Putting It All Together - HyperForm
49
Putting It All Together - HyperForm CAE for Simulation of Metal Forming
• import the CAD model of the punch and die, if available, else derive
it from the component model25
• mesh the blank, punch, die, binder (and ejector, if present) with
shell elements. The mesh should be created at the mid-surface of
the blank, and the clearance between the punch and die should be
captured accurately. Drawbeads are best modeled explicitly, instead
of using analytical definitions.
• specify material properties for the tool – punch, die, binder and
ejector. Since we treat these as rigid (undeformable components)
the values are not critical
• inspect the results – thinning, wrinkling, tool motion and the FLD.
Thinning is often viewed as an animated contour.
Believe nothing, no matter where you read it, or who said it, no matter if I
have said it, unless it agrees with your own reason and your own common
sense
Buddha
25
Remember that this is convenient, but not recommended since it means the
analyst is making assumptions that are best left to the die designer
50
CAE for Simulation of Metal Forming Advanced Topics
Advanced Topics
The simulation of metal forming is a little like car-racing: extremely
satisfying when it works, but it can easily go off the rails. Few of the items
listed in this chapter are essential – they can be ignored unless you are
faced with a problem that requires that little extra.
Commercial Terms
Several steel alloys are designed specifically for their forming characteristics.
Aluminum, Silicon or Manganese are added to molten steel (in the furnace,
before it solidifies) to reduce the oxygen content. Called killed steels
because the metal is less chemically active when cast, these have more
uniform properties than rimmed steels. Rimmed steels, which usually have a
carbon content below 0.15% (as against killed steels which have a content
> 0.25%) are formed because incomplete deoxidation allows the formation
of bottom and side rims that are purer than the rest of the ingot.
• UHSS – Ultra High Strength Steels, with a yield strength > 550
MPa
• DDQ and EDDQ – Deep Draw Quality and Extra Deep Draw
Quality steel
HSS, AHSS and UHSS are more formable, as evident from the low ratio of
the yield strength to the ultimate strength.
The model you create using HyperForm is stored in a binary file with the
extension “.hf”. If the one-step solver is used, no other files are involved or
needed.
In these cases, the data in the HypeForm file is written out to a plain-text
file that’s sometimes called a “data deck” since each line in the text file is
the equivalent of the computer cards that were used to submit data to the
computer in the early days of computing26. The incremental solver in turn
26
See, for example, http://en.wikipedia.org/wiki/Unit_record_equipment
52
CAE for Simulation of Metal Forming Advanced Topics
writes a set of files which you should load for post-processing – to view the
results.
53
Glossary and References CAE for Simulation of Metal Forming
Bending The shaping of sheet metal by straining the metal around a straight
axis. A bending operation compresses the interior side of the bend
and stretches the exterior side.
Binder Bounce On initial contact, the blank holder can bounce. As a result, the
material flows faster for this brief period – it’s not being held as
designed. Faster flow can lead to wrinkles.
Binder The upper and lower holding surfaces (part of the draw die) which
press the metal-sheet against the draw ring to control metal flow.
Blank A flat, precut metal shape ready for subsequent press operation.
The piece of sheet metal, produced in cutting dies, that is to be
subjected to further press operations. A blank may have a specific
shape developed to facilitate forming or to eliminate a trimming
operation subsequent to forming.
Blank The process of determining the optimum size and shape of a blank
for a specific part; the resultant flat pattern.
Development
Bolster plate A plate that is designed to hold in place the lower die shoe. The
bolster plate is attached to the top surface of the press bed.
Clearance The amount of space between the outer edge of the punch and the
inner edge of the die cavity. A proper amount of clearance is
necessary for an effective shearing operation.
Combination Die A die that performs more than one operation (e.g. blanking and
piercing) for each stroke of the press.
Deep drawing The drawing of deeply recessed parts from sheet material through
plastic flow of the material when the depth of the recess equals or
exceeds the minimum part width. A drawing operation where a part
54
CAE for Simulation of Metal Forming Glossary and References
exceeds the minimum part width. A drawing operation where a part
is produced from a blank by the action of a punch in which the sheet
is pulled into a die cavity and the flange of the blank is compressed
in the circumferential direction. The area directly under the punch
remains undeformed.
Die Holder Another term used for the lower die shoe.
Die Set The collective assembly of upper and lower die shoes, guide pins and
bushings, and punch and die retainers.
DQSK steel Drawing Quality Special Killed Steel, a highly formable grade of mild
steel usually aluminum deoxidized and sometimes referred to as
DQAK (Drawing Quality Aluminum Killed).
Elastic limit The maximum stress to which a material may be subjected, and yet
return to its original shape and dimensions on removal of the stress.
55
Glossary and References CAE for Simulation of Metal Forming
Engineering strain The unit elongation given by the change in length divided by the
original length. Preferably called nominal strain.
Engineering stress The unit force obtained when the applied load is divided by the
original cross-sectional area. Preferably called nominal stress.
Forming Limit An empirical curve showing the biaxial strain levels beyond which
failure may occur in sheet metal forming. The strains are given in
Diagram (FLD)
terms of major and minor strains measured from deformed circles,
previously printed onto the undeformed sheet.
Guide Post A hardened rod positioned in the lower die shoe that fits into a
bushing in the upper die shoe to guide the punch during operation.
Guide Post A hardened steel tube that slides over the guide post and directs the
upper die shoe during operation.
Bushing
High strength steel By Auto/Steel partnership definition, any sheet steel product whose
initial yield strength is specified 30 KSI or higher. These include bake
(HSS)
hardenable steels.
Lower Die Shoe The lower plate of a die set that supports the die retainer and die
button.
Major strain Largest principal strain in the sheet surface. Often measured from
the major axis of the ellipse resulting from the deformation of a
circular grid.
Metal clearance Depending on the stock thickness being used to make the part in the
die, it is the running clearance on the bottom of the press stroke
between flange steels or male and female form steels.
Minor Strain The principal strain in the sheet surface in the direction
perpendicular to the major strain. Often measured from the minor
axis of the ellipse resulting from deformation of a circular grid.
Necking Localized thinning that occurs during sheet metal forming prior to
fracture. The onset of localized necking is dependent upon the
stress state which is affected by geometric factors.
Pilot A long, slender punch with a rounded tip used to position the metal
sheet by entering a previously formed hole. Pilots are longer so that
they enter the sheet before other tools form the metal.
Plain-carbon Steel A basic grade of steel, which contains less than 3 percent of
elements other than iron and carbon.
Plastic strain ratio A measure of the normal plastic anisotropy as defined by the ratio of
the true width strain to the true thickness strain in a tensile test.
(r value)
The average plastic strain ratio ( r ) is determined from tensile
samples taken in at least three directions from the sheet rolling
direction, usually at 0, 45 and 90 degrees.
It is a measure of deep drawability.
Press Brake A type of press with an open frame and very wide bed. Press brakes
are often used for bending operations, and they are typically
manually operated.
Progressive Die A die containing a series of stations that perform one press operation
after another in series. A progressive die gradually forms a part as it
moves through the die, and the last operation separates the part.
Punch The tool typically attached to the upper portion of the die set that
shapes or penetrates the sheet metal.
Punch press A machine with a stationary base and an upper ram that moves
along a vertical axis to shear, bend, or form sheet metal.
Punch retainer The device used to mount the punch on the upper die shoe.
Ram The main upper portion of the press that slides up and down within
the press frame. The upper die shoe is attached to the ram.
57
Glossary and References CAE for Simulation of Metal Forming
Station A position within a progressive die where a punch and die perform a
single metalworking operation. Progressive dies consist of a series of
stations.
Stripper A plate designed to remove sheet metal stock from the punch as it
pulls away from the die during the operation.
Thickness strain Thickness strain is the change in thickness of the material due to
forming. Thickness strain or metal thin-out can be measured using
an ultrasonic thickness gauge. It is necessary to do some circle grid
analysis to determine the location of the thickness strain on the
forming limit diagram, but then this technique can be used as a
quick non-destructive test. Since this variable can be most closely
linked to breakage it will provide the primary comparison to setting
the level of critical process variables.
Tool Steel A type of steel designed for excellent wear resistance, toughness,
and strength. Tool steels are typically variations of high-carbon
steels.
Upper Die Shoe The upper plate of a die set that secures the punch retainer.
Wiping die The tool used in an edge bending operation that provides the corner
over which the extended portion of sheet metal is bent.
Yield strength The stress at which a steel exhibits a specified deviation from the
proportionality of stress to strain. Generally, the yield strength is the
measure of the stress at which a steel sample will begin to
58
CAE for Simulation of Metal Forming Glossary and References
measure of the stress at which a steel sample will begin to
permanently deform under a tensile stress.
Yield stress A stress at which a steel exhibits the first measurable permanent
plastic deformation.
References
Eary, D.F. & Reed, E.A. (1997). Techniques of Pressworking Sheet
Metal: An Engineering Approach to Die Design
http://www.autosteel.org
From the American iron and Steel Institute – wealth of information
about steel.
http://www.metalformingmagazine.com
From the American iron and Steel Institute – wealth of information
about steel.
Other Resources
www.altair-india.com/edu, which is periodically updated, contains case
studies of actual usage. It also carries tips on software usage.
59
Glossary and References CAE for Simulation of Metal Forming
Also remember to check the units in your model – they must be consistent!
The recommended units for incremental analyses are:
Length mm
Stress MPa
Blankholder force N
Density mg/mm
Time s
Velocity mm/s
60