2. Satic Implicit Static Explicit Dynamic Explicit Smooth Particle Hydrodynamics Element Free Galerkin Method Moving Least Square Method Approximation Reproducing Kernel Particle Method Possible simulation techniques in metal forming

3. Modular Structure of Forming Processes reference: K. Lange, Stuttgart

4. Product and process design for net shape manufacturing

5. Name Manufacturer, country TypeApplication ABAQUS HKS, USA implicit generally, non-linear MARC MARC, USA/NL. D implicit generally non-linear NIKE 3D LSTC, USA implicit generally non-linear LARSTRAN LASSO, D implicit generally non-linear INDEED INPRO, D implicit sheet metal forming ITAS3D Prof. Nakamachi, J explicit, static sheet metal forming DYNA3D LSTC, USA/ explicit, dynamic crash, bulk, sheet metal PAM-STAMP ESI, F/D explicit dynamic sheet metal forming Optris Dynamic Software, F explicit dynamic sheet metal forming MSCDYTRANMacNeal-Schwendler explicit dynamic sheet metal forming ABAQUS-explicit HKS, USA explicit dynamic crash, bulk, sheet metal AUTOFORM AUTOFORM, CH Spec. formulation implicit sheet metal forming Autoforge MARC, USA/NL, D elastic – viscoplastic bulk, forging DEFORM Batelle, USA, D rigid – viscoplastic bulk, forging FORGE 2/3 CEMEF, F rigid – viscoplastic forging ICEM – STAMP Control Data, D one – step method sheet metal forming ISO – PUNCH Sollac, F one - step method sheet metal forming AUTOFORM One – step AUTOFORM, CH one – step method sheet metal forming FASTFORM FTI, Canada one – step method sheet metal forming SIMEX 2 SimTech, F one – step method sheet metal forming Commercially available FE programs for forming process simulation

6. TopicsTopics Why Forging Simulation? Why Forging Simulation?

7. Conventional Product Development Expensive Fixes: visible defects press capacity exceeded underfilling (drop forging) high localized die loads More Expensive Fixes: “invisible” defects unacceptable tolerances Most Expensive Fixes: short die life unstable process conditions Customer Specs Design & Tool Dev. Prototype Testing Pilot Stage Mass Production Reduce ‘s, improve time to market !

8. Simulation-Aided Product Development simulation Customer Specs Design & Tool Dev. Prototype Testing Pilot Stage Mass Production time to market Prototype Testing Pilot Stage Mass Production shorter time to market Pilot Stage Mass Production Be First to Market with Better and Cheaper Products ! Less Fine Tuning: improved quality less invisible defects Shorter Development Time: less trial and error less blocking of production line optimized for available press less visible defects

10. Additional Benefits of Simulation Other benefits: reduce number of mfg stages more insight into mfg process less machining operations expand state of the art more successful bids Optimization during product life time: extend die life minimize material scrap optimize process conditions optimize press capacity utilization simulation Customer Specs Design & Tool Dev. Prototype Testing Pilot Stage Mass Production Reduce Costs during Mass Production !

11. Why Simulation Reduce Time to Market Reduce Time to Market Reduce Cost of Tool Development Reduce Cost of Tool Development Predict Influence of Process Parameters Predict Influence of Process Parameters Reduce Productions Cost Reduce Productions Cost Improve Product Quality Improve Product Quality Better Understanding of Material Behavior Better Understanding of Material Behavior Reduce Material Waste Reduce Material Waste

12. Manufacturing Results Accurately predict the material flow Accurately predict the material flow Determine degree of filling of the swage or die Determine degree of filling of the swage or die Accurate assessment of net shape Accurate assessment of net shape Predict if laps or other defects exist Predict if laps or other defects exist Determine the stresses, temperatures, and residual stresses in the work piece. Determine the stresses, temperatures, and residual stresses in the work piece. Determine optimal shape of preform Determine optimal shape of preform

13. Material Behavior Determine material properties such as grain size Determine material properties such as grain size Determine local hardness Determine local hardness Predict material damage Predict material damage Predict phase changes and composition Predict phase changes and composition Simulate the influence of material selection Simulate the influence of material selection

14. Tool Results Determine the forming loads Determine the forming loads Determine the stresses in the tools Determine the stresses in the tools Evaluate tool wear or fatigue Evaluate tool wear or fatigue Simulate the influence of lubrication Simulate the influence of lubrication Optimize multi-tool process Optimize multi-tool process

15. Simulation allows you to capture behavior that can not be readily measured – providing deeper insight into your manufacturing processes

16. Damage Prediction - Chevroning Multi-stage Hydraulic Press with Annealing Transfer Press

17. Possible forming of laps and its prediction through simulation technique

18. Kinematics Placing the workpiece Placing the workpiece Closing the tools Closing the tools Forming process Forming process Removal of the tools Removal of the tools Extraction of the workpiece Extraction of the workpiece –Including spring-back Subsequent cool-down Subsequent cool-down

19. Flexible Tool Definition Rigid Tools Rigid Tools Deformable Deformable Direct CAD NURB Description Direct CAD NURB Description

20. Material Models Elastic Plastic Elastic Plastic Rigid Plastic Rigid Plastic Material Database Material Database Isotropic hardening Isotropic hardening Cowper-Symonds Cowper-Symonds Power Laws Power Laws Johnson-Cook Johnson-Cook Kumar Kumar Grain Size Prediction Grain Size Prediction Phase Changes Phase Changes

21. Effects of Elasticity Elasticity of Tools Elasticity of Tools Prestressed Dies Prestressed Dies Residual Stresses Residual Stresses Behavior of part during ejection or removal Behavior of part during ejection or removal Determination of tolerances Determination of tolerances

22. FrictionFriction Friction Influences: Friction Influences: –load and energy requirements –metal flow –pressure distribution –die wear Friction Models Friction Models –Coulomb friction –plastic shear friction –combination User-extendable Database User-extendable Database

23. Visualization Tracking of Material Particles Tracking of Material Particles Flow Line Images Flow Line Images Time History of Tool Forces Time History of Tool Forces Deformation of Workpiece Deformation of Workpiece Contour Plots of all Quantities Contour Plots of all Quantities

24. Material Cost Savings The cost of NOT doing it right the first time?

25. Thank You!