1. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. A Case Study of Die validation of fuel tank using HyperForm 7.0 HyperForm 7.0

2. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Component 250 mm 350 mm

3. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Material Properties The material grade specified for this fuel tank is IFCS Material Properties specified by raw material supplier. – Young’s Modulus, E : 215000 MPa – Poisson's ratio, nu : 0.26 – Yield Stress, σ : 136MPa – Strain Hardening index, n: 0.21 – Anisotropy ratio, r bar : 2.31 – Strength coefficient, K : 12603 MPa

4. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Stages in simulation Component Feasibility Study Die Face Design Virtual Tryout Blank Optimizer

5. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Manufacturing Feasibility Study Mid surface Extracted

6. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Blank developed

7. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Blank profile ( after adding Trimming allowance)

8. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Die Face

9. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Virtual Tryout and Blank optimization Tool build Process parameters specification – Tool Motion – Tool Load – Draw bead location – Draw bead parameters – Lubrication Blank Optimization

10. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Tool Build

11. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Iteration 01 Process parameters: – Blank Holding Force: 40 Ton – Friction: 0.125 – Draw beads: As per the table (next slide) Blank shape:

12. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Draw beads ( Iteration 01) BEADSDB1DB2DB3DB4DB5DB6DB7DB8DB9DB10DB11 DB Height55555555555 DB Rad55555555555 Sh Rad44444444444

13. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Formability plot

14. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Next 10 iterations IT no.Input parametersResults 01Blank holding force 50 tons, Draw bead parameters 5 x 5 x 4. Die entry radius R20. Heavy wrinkles till bottom 02Blank holding force increased to 80 tons. Wrinkles reduced at straight edges only. Radius portion with heavy wrinkles. 03Die entry radius at radius portion morphed to R17.5 using Hyper morph. Wrinkles at radius portion reduced 04Draw bead at straight portion tightenedWrinkling tendency at straight portion reduced. 05Draw beads at radius portion tightenedResulted in crack 06At radius profile radial draw beads added instead of straight. Wrinkling tendency reduced but still persisted. 07Draw bead at radial portions tightenedResulted in crack 08Blank is chopped off to reduce blank holding force. Crack vanished but little wrinkling tendency which can be avoided in tryout easily.

15. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Morphing Die Entry Radii locally

16. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Morphing Die Entry Radii locally

17. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Draw beads ( Iteration 02) BEADSDB1DB2DB3DB4DB5DB6DB7DB8DB9DB10DB11 DB Height5535552.55555 DB Rad55355555555 Sh Rad2.51.9832.42.72.523.943.52.4

18. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Formability plot

19. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Thinning plot

20. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Finished Part

21. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Our vision towards CAE….. 1. To cover all forthcoming developments & existing products through CAD and CAE. through CAD and CAE. 2. Improve upon accuracy level of analysis. 3. Cover other applications of analysis as well like PRODUCT OPTIMIZATION. OPTIMIZATION.

22. Supreme Group People Press, We Impress Quality First TS-16949 Certified Co. D-U-N-S Number 86-246-4013 ISO/TS-16949:2002 Certified Co. Thank You….