advance in fem simulation and its related technologies in sheet metal forming

1、Keynote Papers Advance in FEM Simulation and its Related Technologies in Sheet Metal Forming A. Makinouchi’, C.Teodosiu2 and T .Nakagawa ( I l 3 1 Material fabrication Lab., RIKEN, Wako, Japan 2 LPMTM-CNRS, Universite P

2、aris Nord, Villetaneus, France 3 IIS, The University of Tokyo, Roppongi, Minato-ku, Tokyo, Japan Abstract This paper presents an overview of the current state of sheet metal forming simulation and related technologies em

3、ployed by automakers and steel sheet suppliers. For this purpose the authors visited industries in Europe, Japan, and the United States, to discuss the above-mentioned issues with engineers and researchers. Softwares use

4、d in each industry are shown in tables and evaluation of finite element cods from industrial users are also summarized in a table. Based on those information the future direction of research in this field is suggested. K

5、ey words : sheet metal forming, simulation, finite element method, CAD 1. INTRODUCTION The automotive industry faces world-wide serious challenges: fierce market competition and strict governmental regulations on

6、 environment protection. The strategies of the automakers to meet these challenges is sometimes called the 3R Strategy: Reduction in time-to- market, reduction in development costs to gain competitiveness, and reductio

7、n in the vehicle weight to improve fuel efficiency. The solutions to achieve this triple goal are essentially based on the implementation of CAD/CAE/CAM technologies in product development and process design. A very sign

8、ificant component of this endeavour is focused on the reduction of the tooling costs and the lead-time related to the stamping of autobody panels, even under increasing technological difficulties such as the use of alumi

9、num alloys and high-strength steels, and requirements for higher geometrical accuracy of stamped parts. To deal with the problems brought about by these trends, which are beyond past experience, numerical methods fo

10、r sheet forming simulation become more and more important, replacing the physical tryout of stamping dies by a computer tryout. The success of numerical simulation depends mainly on the advances in forming simulation cod

11、es, but progress in other related technologies is also important. Examples of related technology are the CAD systems that rapidly construct and modify tool surfaces, modern mesh generators to, more or less automatically,

12、 create FE- meshes on CAD surfaces, visualization hardware and software, which enables users to grasp the huge data, and, finally, the computer hardware, which makes it possible to perform large scale simulations within

13、 reasonable time. The objective of the paper is to present an overview of the current state of sheet metal forming simulation and related technologies realized in industries, and to suggest the future directions of re

14、search. Many international conferences have been held and numerous papers are published related to sheet metal forming simulation in the 1980’ and 1990’ . However, the information obtained through these events is not s

15、ufficient to address the above issues. For this reason the authors decided to visit automotive industries and sheet steel suppliers in Europe, Japan and the United States to discuss these specific topics with engineers

16、and researchers working at die shops and in sheet stamping sections of industries. 2. HISTORICAL BACKGROUND Analytical study of sheet metal forming process was already started in the middle of this century[l,2], and num

17、erical procedures (finite difference methods) were applied to analyze axisymmetric drawing process in the 1960’ [3]. Although such work contributed greatly to develop the theory of sheet metal forming analysis, this kind

18、 of approach could not be applicable to the actual production parts. Non-linear finite element methods opened the path for the simulation of real industrial stamping processes [4-61. A symposium on computer modeling of

19、 sheet metal forming process was held in Ann Arbor, Michigan in 1985 [7], in which three dimensional auto-body panel forming processes are modeled by elasto-plastic finite element methods using shell elements [8,9]. In t

20、hese studies drawing process of a lift window outer and binder wrapping process of a deck-lid were simulated, but they were in the stage of testing and evaluation, since finite element Annals of the ClRP Vol. 47/2/1998 .

21、 64 1 Keynote Papers 'Company Place Name Visited Daimler Benz Renault Automobile Volvo Car Sollac Sindelfingen Plant Guyancourt Technocenter Olofstrom Engineering Montataire Centre Germany France Sweden

22、 d' tudes et de Developpement Simulation Software . . France AUTO FORM SIMEX AF ONE STEP ISOPUNCH LS-DYNA3D OPTRIS AUTO FORM AUTO FORM OPTRIS OPTRIS INDEED ISOPUNCH LS-N I KE3D PAM-STAMP LS- DY N

23、A3D PAM-STAMP CAD Mesh AF ONE STEP CATIA I-DEAS CATIANAMOS SYRKO ( in house ) MEDINA HYPER MESH DELTA MESH TRANSK EUCLID i Generator 643 DELTA MESH DELTA MESH Company Chrysler Ford Motor National Stee I Pl

24、ace Technical Center Research Laboratory Product Application Center Name Visited Auburn Hills, Michigan Dearborn, Michigan Livonia, Michigan Simulation LSDYNA 3D MTLFRM DYNA 3D Software AUTO FORM OPTRIS FAST

25、-FORM3D AUTO FORM (EU) CAD CATIA I-DEAS CATIA US Steel Troy, Michigan DYNA 3D Mesh Generator (PDGS) DELTA MESH I-DEAS (for tool surface) DYNA FORM HYPER MESH DYNAFORM in house software HYPER MESH for sheet