Altair India

HYPERWORKS FOR STUDENTS

Projects using HyperForm and Radioss

Simulation of Springback in Aluminum





Areas covered:

Data import and geometry cleanup.

Layout and organization of components of the press-tool.

Specification of process parameters.

Controlling the incremental solver for explicit forming analysis and implicit springback analysis.

Description of the Problem: Aerospace components often use aluminum for the weight advantage it provides over steel. Unfortunately, aluminum has two disadvantages from a forming perspective. First, its behavior is more sensitive to the strain-rate than ordinary steels. Second, it is more prone to springback - recovery of elastic strains after forming. The component that has been supplied to a die designer is geometrically simple, but the press shop has no experience in working with Aluminum. The range of forces to be used, for both the blank holder and the ram, are to be verified. Further, the die designer has to confirm whether the component will pass dimensional checks after forming, or whether springback must be compensated for - either by forming the component a little too much or by using a subsequent operation. So the analyst must cover two distinct steps. The first is to check for the effect of springback. The task is complicated by the fact that the press shop has not supplied material data for Aluminum. Aerospace manufacturers tend to be very specific in the grade of alloys that are permitted, so the die designer wants to supply, along with the design, the effects of changes in the material properties of some common Aluminum alloys on the performance of the process. Next, the analyst must establish the process parameters - forces, lubricant, etc. - and, if springback is significant, suggest how the press shop can deal with the problem.

Blank Size Optimization for an A-Pillar





Areas covered:

Data import and geometry cleanup.

Layout and organization of components of the press-tool.

Specification of process parameters.

Use of HyperNest for blank-yield calculations.

Description of the Problem: A press-shop is quoting for the manufacture of a part of an "A Pillar" of a car. The component has a nominal thickness of 1 mm and is made of CRDQ (Cold Rolled Die Quality steel). The product data has been supplied, based on which the press-shop has arrived at a preliminary die design. The die designer has created the die-face, using the CAD model of the component as the base. There are three problems the press shop wants to address. The first problem is to estimate several process parameters. Principally, the analysis must indicate whether or not draw beads will be required, and whether a lubricant must be used or not. The component specifications call for the thickness to be within 12% of the nominal thickness. Next, the size of press that will be needed must be estimated. That is, the press tonnage must be calculated. Finally, since the press shop will have to manufacture the components if it wins the order, it would be to its advantage if it can optimize the blank shape. Even though the component is a little large, the press-shop wants to check if a "trimless" blank can be specified. This allows the press shop to save on the post-forming trimming operation. If not, can wastage be reduced? A preliminary blank has been given, but this is only indicative: the press shop wants to know the best blank shape.

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