Hyperworks CAE paketinde yer alan saç metal şekillendirme (derin çekme) yazılımı Altair HyperForm kullanılarak gerçekleştirilen çalışmalara ait 2011 Altair Hindistan HyperWorks Kullanıcı Konferansı makalelerini aşağıdaki bağlantı adreslerinden indirebilirsiniz.
The process of new product development through sheet metal forming is one of the most common manufacturing processes existing in industries; however it is not easy to design the process and the tools for most of the components. Material breakage, wrinkling, shape defects, cracks are the defects encountered in sheet metal forming operation. Such defects can be foreseen during die development using HyperForm and Radioss forming simulation technique, and through simple design change their occurrence can be prevented during manufacturing.
The paper converses the integration of sheet forming simulation in the tool surface development and process development phase. It discusses about the different results obtained from the simulation which help to derive the solution if the component fails during forming. Virtual tryouts results in reduction of time and cost. It is helpful in deciding the tonnage, geometry and the material properties of the product to design the manufacturing process effectively.
Representing pre-stresses due to forming has become an important criterion as the CAE analyst’s goal is to predict a crash test mode accurately. For extracting pre-stresses, HyperForm is one of the proven CAE forming tools. This paper is about a methodology of automating the forming process by effectively using Altairs HyperStudy, Hyperform and RADIOSS solver for optimization of various parameters like blank holding pressure, sliding friction, draw bead restraining force and thickness of the component to meet formability requirements like FLD ( forming limit diagram), % thinning and plastic strains. This paper also shows the method to extract the pre-stress from forming simulation and apply to a crush-can component of a passenger vehicle. Finally there is a comparison of crush-can behavior with and without pre-stress on a crash model for FMVSS208 35mph flat frontal test mode.
The paper deals with the spring back analysis of the wire tunnel of a missile. The Wire tunnel is one of the critical components of the missile and houses the bunch of wires which communicates the electric signals from one section of the missile to another. The Wire tunnel is a sheet metal component and made up of Maraging steel. Sheet metal forming simulation using HyperForm was carried out to predict the sprig back and accordingly die and punch were modified and fabricated to achieve the component within stringent tolerance requirement.
AMW Asia MotorWorks – Validation Of Innovative Notion On Tooling For Enriched Product Thru User Process Of Altair HyperForm
The dictum of every business is to deliver the product with enriched quality & services with optimum cost & time to customers. Every competitive industry will not end by not only proving the product and also focus on continuous improvement to enrich the quality, cost & time for the existing product. Engineering & design team is also liable to achieve such focus on improving the process structure with various innovative concepts. Simulation based virtual validation helps to enhance the product, reduced the process cost & reduction of investment for new manufacturing line.
Marathwada Institute of Technology — Formability Analysis for Trapezoidal Cup Forming Using HyperForm
Majority of automobile and appliances components are made by deep drawing sheet metal process. So these growing need demands a new design methodology based on metal forming simulation. With the help of metal forming simulation we can identify the problem areas and solutions can be validated in computers with out any expansive shop floor operations prior to any tool construction. Metal forming simulation is also helpful at the product and tool design stage to decide various parameters. Optimization of process parameters in sheet metal forming is an important task to reduce tryout and manufacturing cost. To determine the optimum values of the process parameters, it is essential to find their influence on the deformation behavior of the sheet metal. This paper describes the methodology by which the influence of various parameters on deformation behavior of the sheet metal can be predicted and the data of post processed result can be used during product design and tool design. The virtual FE simulation can predict various defects during deep drawing process at the product design stage. The study performed in this paper to predict the effect of parameters on formability of a trapezoidal cup using Altair HyperForm radioss predictive tool. The formability analysis is performed for various cases of different values of parameters blank holding force and friction coefficient and various virtual tryout set is developed and thickness variation are analyzed. The die, punch, binder and blank are the main components developed as virtual tryout set.