Task: Functional Design in a MultiMaterial Mix that Fulfills Specification
Cold Formed Steel
Aluminum Sections Sections
Cast Aluminum
Hot Formed Steel Sheet Aluminum http://boronextrication.com/201 http://boronextrication.com/ 2011/08/2012-audi-a6-bo 1/08/2012-audi-a6-body-structure/ dy-structure/
General Trends in the Automotive Manufacturing Manufacturing Industry Light weight • Mixed materials for functional design desi gn (Steel, Al, Mg, Carbon Fiber), New Joining and Multi-Domain Optimization to validate performance.
Market Trends in Steel HS Steel Standard Steels
Hot Formed Steel
www.carbodydesign.com
UHS Steel
Trends for Forming Processes of Light Metals Krajewski, GM, Body & Assembly Congress Troy 2011
Market Trends in Aluminum
Cast aluminum 44% Aluminum sheet metal 28% Aluminum sections 17% Steel 8% Other materials 3%
http://boronextrication.com/tag/body-structure/
Those are the Engineering Disciplines Behind
Advancement in Vehicle Advancement Vehicle Structures & Safety Materials Optimization for Body Engineering Body Engineering – Engineering – Digital Digital Optimization Manufacturing Engineering
This is the Job to be Done
“Virtual Prototyping means reducing tests and physical prototypes with virtual test and prototypes. This saves the cost for the physical try-out. Also Also the time it takes to do the try-out try- out is eliminated” The mandatory condition is the ability to deliver results good enough to reliably replace the physical tests, in a time frame significantly shorter than physical try-out would be
About ESI Provider of Virtual Prototyping for the Industrial World World
ESI is a world leading software editor for the numerical simulation of prototype and manufacturing process engineering in applied mechanics
ESI Covers Most Aspects Aspects of Body & Assembly
Advancement in Vehicle Advancement Vehicle Structures & Safety Materials Optimization for Body Engineering Body Engineering – Engineering – Digital Digital Optimization Manufacturing Engineering
ESI Virtual Prototyping •
Multi-Domain performance engineering solutions
•
Including the coupling effects between domains and mechanical impact of manufacturing processes
•
Supported by a unified Visual Environment Platform, designed to enable multi-task automation and support Engineering Workflow management and collaborative Engineering.
Virtual Manufacturing
Comfort
Drivability
Stamping
Assembly
Acoustics
Crash & Safety
Stiffness & Strength
NVH & Durability
End-to-End Virtual Prototyping of a Stamped Component Full chain simulation under Visual-Environment, in early design phase
Tool milling milli ng
PAM-STAMP 2G: Full chain simulation with hemming assembly PAM-DIEMAKER for CATIA V5 Tool design
Forming
Springback
Restrike
Springback
Flanging
Springback
Hemming
Requirements on: - Geometry? -Cosmetic Defect? -Material, Thickness?
Optimized production time & tooling costs
Springback
Assembly
Virtual Performance Solution Crash, Strength, NVH, Durability
Requirements on: Requirements on: - Geometry? -Material, thickness? -Cosmetic Defect?
Less hardware prototypes, optimized safety margin
End-to-End Virtual Prototyping of a Hot Formed B-pillar Tool milling mil ling Full chain simulation under Visual-Environment, in early design phase PAM-DIEMAKER for CA CATIA TIA v5 Quick tool design
PAM-STAMP 2G Fast Hotforming with metallurgy
Material Thk,, ε, σ… Thk
VPS Crash (including spot welds rupture), Strength, NVH, Durability
% of Martensite
End-to-End Virtual Prototyping of a Composite B-pillar Lay-up strategy defined In CATIA CPD or SIEMENS FiberSim
Draping and RTM simulation with PAM-RTM
Lay-up + material
Structural analysis with Virtual Performance Solution Part design change
E/E0=AE*exp(B E/x)
Draping and Porosity affect Mechanical properties
/ 0=AT*exp(B T/x)
s s
Those are the Engineering Disciplines Behind
Advancement in Vehicle Advancement Vehicle Structures & Safety Materials Optimization for Body Engineering Body Engineering – Engineering – Digital Digital Optimization Manufacturing Engineering
Materials Optimization Covers the Following
Die Face Design & Early feasibility based on geometry Cold precision forming • Standard processes • Advanced springback for advanced materials • Class A buy-off including all following operations • Cosmetic defects
Hot forming Casting
Parts Covered
Benefits of Materials Optimization with Virtual Sheet Metal Forming Time reduction Early evaluation of manufacturing ability Reduction in the development times Reduction of the try-out times Quick response to needed modifications
Bidding and Planning
Cost reduction Cheaper products Reduction of the die costs Press down sizing Increase of reliability
Die Face Design and Validation
Increase of product quality Optimal selection of the work piece material Production of more complicated parts Know-how accumulation for new materials Press repeatability Altan 2012
Precision Forming – Forming – Cold and Hot
Sheet Metal Forming
EARLY EARL Y FEASIBILI FEA SIBILITY TY
Major Trends in Sheet Metal Forming
Only a few parts will remain mild steel Complex technology - presented in a simple and accessible manner From feasibility over precision forming to milling – milling – one one model based on geometry Standard forming operations and compensation will go into early feasibility Springback / precision needs to be as good as humanly possible Robustness is interesting in case the major variables are matched
Expected Solution
Easy to use product Several people using the tool would arrive at the same result Minimum training requirements Integrating customer’s experiences and best practices Without need in specific numerical or finite element knowledge All that for a market price
Die Face Design Next Generation – Generation – Switch from Mesh…
Die Face Design Based on Mesh
Die Face Design Based on Geometry
….to Geometry Approach - Design is Based on Geometry!
New Proposed Work Flow for Die Design
The conventional workflow is shown at the top and the new proposed workflow based on CATIA V5 / Visual Environment is represented below – below – clearly clearly showing the potential time savings
Die Face Fac e Design Desi gn in CATIA CATIA Die Maker - 15 to 20 Min Part preparation
Export
~ 10 minutes Blankholder design
~ 1 minutes
~ 1 minutes Addendum design
~ 5 minutes
Part Exchange - Initial Model and New Model
Different outlines!
Capabilities of Part Exchange
Fully or semiautomatic replace: Automatic recognition of new flanges Automatic definition of symmetry E.g. recognition of redundant rolling cylinder curves Possibility to add new functionalities (e.g. rolling cylinders, profiles,..) Recognition of missing input (flange) surfaces for part on binder Automatic or manual re-assigning start points of floating profiles
The Total Time to Target is in this Example Less then 2 Minutes
Presented by Daimler AG at German User Forum 2011 „The milling result is very good and for a prototyping tool more than sufficient. The programming in TEBIS caused no problems whatsoever.“ „The Offset-Surfaces Offset-Surfaces could be processed directly in TEBIS without any problems.“ Uwe Fisch er Mercedes Mercedes -Benz Cars R&D
Following Operations Transfer of geometry via IGES
Final forming simulation Springback compensation Return of the compensated mesh into CATPart Overbending of the „die set“ with DIGITIZED MORPHING
Offset Generation of solid tooling
Summary
PRECISION FORMING
Precision Forming F orming - This is the Task Task
…and make sure material properties are right for performanc performance e considerations
Positioning
"Make sure that the panel comes off successfully in the first shot"
Examples: Inverse/One-Step Simulation Blank development
Product design
Thinning prediction
Forming Limit Diagram (FLD)
Incremental Simulation: Overview Applicable to : Progressive dies Line dies Transfer dies Deep draw Crash forming Superplastic forming Sheet & tube hydroforming Tube bending Tube and sheet hydroforming Hot forming Ironing Coining Stretch forming Flex forming
Material: Titanium Aluminum Stainless Copper HSS …
Example Progressive Die Predicting common defects such as splits, wrinkles, spring back and material thinning on computer
High thinning
Providing customers with “right first time tooling” to run production with a minimum of manufacturing risk
Standard Stamping
Wrinkling prediction
Cracks prediction -Process requiring Solid elements -Strong Solids capabilities in PAM-STAMP2G (also used for coining)
Why is High Strength Steel more Challenging
Mild Steel
590TS
980TS
AHSS (Advanced High Strength Steel) - Precision Forming
Mild Steel
590TS
980TS
Bad Formability
Large Springback
PamStamp 2G v2012 includes more accurate and faster springback
for stamping of Ultra High Strength Steel
Spring-back/Compensation Unbending
Opening Wall curvature
Twisting
Find the Optimal Blank Size & Trim Lines with Automatic Optimization
Blanking
Forming
Springback
Restrike
Springback
Flanging
Trimming
Springback
Flanging
blank shape
Forming
trim lines
Trimming
Springback
Restrike
LINE DIE OPTIMIZATION Initial Blank shape optimization
Before optimization 18% up to 1mm
1st forming
2nd forming
restrike
After optimization 95% up to 1mm
Line Die – Die – Full Full Chain – Chain – Simulation, Simulation, Optimization, Quality Control
Forming
Springback
Restrike
Springback
Flanging
www.carbodydesign.com
Springback
Hemming
Springback
Virtual Prototyping Prototyping of all OPs
Source: Europam Toulouse 2006
Forming
Springback
Restrike
Springback
Flanging
Springback
Formability Analysis Analysis of Complex Automotive Panels Panels and Full Process / Full Full Cycle Simulation
Process validation and optimization, defects prediction before try-out
Correction of springback
Forming
Springback
Restrike
Multi-Ops Draw die compensation
Automatic draw and trim die compensation
Springback
Flanging
Springback
Die compensation Compensate die from multi-OP springback
Solve transfer: adapt die from previous or next OPs
Y-T -Tec ec manufactur manufactures es an a n ultra ult ra high high strength s trength steel bumper with PAM-ST AM-STAMP AMP 2G's springback correction “Using the Yoshida-Uemori Yoshida-Uemori model in PAM-STAMP PAM-STAMP 2G improves the accuracy of springback prediction to a point where it becomes possible to determine effective qualitative countermeasures. countermeasures. By analyzing the stress and strain accumulated during forming, we were able to determine and eliminate the cause of poor dimensional accuracy. accuracy. Thanks to PAM-ST AM-STAMP AMP 2G, we reduced the number of modifications on the stamping tool even in cases where the parts’ formability was was challenging, such as Ultra High Strength Steel parts.” Hiroki Kondo, Deputy Manager, Advanced Press Engineering Group/Dept. Y-Tec Corporation
Improvement of springback by reducing plastic strain Stress components which cause springback
Courtesy of Y-Tec Corporation
Gestamp successfully brings to market a weight-optimized B-pillar stamped from tailored blank using PAM-STAMP 2G
“We achieved very good results thanks to the accuracy of the simulation using PAMSTAMP 2G. We were able to use the springback prediction tool to evaluate the die compensation, despite the complexity of such a case with three different thicknesses and two weld lines.”
Eduardo Sulato and Fábio Lichtenthäler Engenharia da Matriceria Gestamp Automoción Gestamp Automoción S.L. S.L. Courtesy of Gestamp Automocion
Hot Forming - Formability Temperature on blank / tool
Martensite fraction during quenching After 4 s
After 8 s
After 14 s
Cooling Simulation of the Dies
3D tools with cooling channels
Tool temperature at the end of quenching:
Courtesy of: AP&T
Temperature at the End of Forming and Quenching
Temperature at the end of forming
Courtesy of: AP&T
Temperature at the end of quenching
Casting Covers all Aspects of Components
Microstructure
Defects
Properties
“The whole is more than the sum of its
States
Dimensions
parts” Aristotle
Summary
NON-METALLIC COMPONENTS
-to-End Virtual Get it right™ with End End-to-End Prototyping Solutions Test it right
Component simulation
System-level Simulation
Deliver it right
Product Life Cycle Infusion
Build it right
Draping
Forming
End-to-End Virtual Prototyping Solution allows customers to deliver the
physical prototype right the first time.
Composites Materials and Processes
Reinforced Thermoplastics Injection molding Thermocompression
Mechanical Properties / Material costs
Press Forming
Unidirectional
2 mm
Mats (GMT) Short fibers Long fibers unreinforced
Textile Fiber length
Design flexibility / production rate
Reinforced Thermosets
6 mm
20 mm
BMC
SMC
RTM / Infusion - Vacuum Forming
Thermoforming & Blowforming Simulation Evaluate and optimize Mold geometry Process conditions Vacuum strategy Molding temperature
Through the prediction of Wrinkles Thickness
Taking into account Thermal & strain rate effects
Industrial Examples of Applications: Applications: Blow Forming (Gas Tank)
Sag under gravity (self-weight) Blowforming
Thinning (%) Distribution
The Main Composites Manufacturing Options Pre-Pregs Lay pre-cut individual individual plies plies to build the laminate OR forming of complete pre-impregnated laminate
Draped preform Coutesy Renault
Cure at high temperature and pressure in an Autoclave OR curing OR curing in forming tools (OOA) Autoclave
LCM (Liquid Composites Molding) Lay pre-cut dry fabrics to build the laminate OR Forming OR Forming of dry fabrics Injection/Infusion of dry fabrics Curing in Injection/Infusion tools LCM Bracket Courtesy: CRC –ACS 2000+
Pre-Preg Forming Simulation Evaluate different forming strategies: Stamping, diaphragm (single or double) forming, thermoforming Clamping conditions, process parameters (tool velocity velocity,, temperature, pressure…) Different Lay-up strategies
Upper tool
4 plies
Lower tool Simulation setup
ESI solutions can help you: Reduce wrinkling Eliminate bridging Predict thickness of material after forming
Initial flat pattern
Optimized flat pattern
Deliver optimum flat patterns Determine final fiber orientation
Poor part quality
Improved part
Aircraft Wingbox Simulation Simulation – – 8 8 Plies (UD)
“As “A s-built” Fiber Orientation
Thermoforming Process
Actual Formed Part
Simulated Part
Courtesy: British Aerospace
Autoclave Process Process Draping
Curing
Fluid-Flow & Heat Exchanges Calculation
Thermo-Mechanical Calculation
Demolding
Thermo-Mechanical Calculation
Internal stresses generation
Local material properties modification
Stress release
Liquid Composites Molding Simulation PAM-RTM can evaluate and optimize Injection strategy (RTM, (RTM, VACUUM INFUSION, …) VARTM…) VARTM Injection pressure and flow rate Injection gates, vents and vacuum ports location Molding temperature Flow media
Through the prediction of Dry spots Filling and curing times Flow front velocity / Fiber washing Pressure in the mold
Taking into account Fiber angle variation (permeability variation) of the preform
Resin Flow Front Analysis Analysis
CF Floor Pan Infusion – Courtesy Courtesy TECABS: RENAULT RENAULT – Mines Douai
Effects of Injection Conditions onto Mechanical Performance For high performance composites, formation of micro-voids inside the (J. Bréard) fiber tows should be minimized Macro voids Inter-tow
Micro voids intra-tow Micro-voids are directly proportional to the resin velocity Critical impregnation velocity
Influence of Porosity on Stiffness & Strength Draping and RTM Model
Lay-up definition
Lay-up + material
Design Iteration
Strength analysis
Draping and Porosity effect on mechanical properties
Simplified Process Setup for Engineers
Visual-Mesh
Read multiple native CAD models – models – CATIA, CATIA, Pro/E, UGS NX, etc. etc. Create stamping tools – tools – blank, rubber pad, etc. Execute simple model operations like translate, etc.
Visual-SDK, Visual-Process Exec
Visual-Viewer
Create simulation process in wizard mode. mode . Encapsulate PS2G PS2G to to generate the process.
Create Process block library for future use
Display results Extract reports
What Makes the Difference: Joining & Full Process Chain for Forming 1 Draw
2 Trim
3 Flange
4 Restrike
5 ........
6 Welding Roll Hemming
OP 20 & 30 Casting …..
OP 40, 50, ….. Assembly
Those are the Engineering Disciplines Behind
Advancement in Vehicle Advancement Vehicle Structures & Safety Materials Optimization for Body Engineering Body Engineering – Engineering – Digital Digital Optimization Manufacturing Engineering
Manufacturing Engineering Covers the Following
Hemming
Cold and hot joining (welding)
Welding including history from sheet metal forming
Roll Hemming
