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Simulation Of SPF (SIM-O-SPF) Quick review and update

Explore advancements in SPF simulation processes with PAM-STAMP 2G, focusing on die design, springback prediction, and cost estimation. Learn about new developments and partnerships to enhance sheet metal forming techniques. Join the forum to share knowledge and improve SPF simulations for aerospace, rail, and automotive industries.

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Simulation Of SPF (SIM-O-SPF) Quick review and update

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  1. Simulation Of SPF (SIM-O-SPF)Quick review and update Rajab Said 7th / Oct/ 2009 SPF Committee - IOM3

  2. Outline of Presentation • PAM-STAMP 2G, Simulation of SPF and other Sheet Metal Forming processes. • Reminder of what SIM-O-SPF is about..? • Update on developments with Industrial Partners • Proposals from Academic Partners • Actions and Timeframe

  3. The Complete solution for Die Design & Sheet Forming PAM-INVERSE PAM-QUIK-STAMP Plus PAM-AUTOSTAMP DIEMAKER

  4. AUTOSTAMP for the entire cycle of Sheet Metal Forming Process Springback

  5. Blank Shape prediction for Cost estimating Part Feasibility assessment to guide Die Design PAM-INVERSE

  6. Die Design Radius: r=10  r=35.08 Thinning: 46.6  30.7 [-] Addendum optimisation

  7. PAM-DIEMAKER Module Re-engineering of local zones Small modifications to existing dies DIEMAKER model after hiding of flanges Surface generation Tool geometry Developed flange

  8. Springback compensation methodology Initiated by / collaboration with Renault / Arcelor Complements other SB compensation methodologies Die Compensation Example from Mitsubishi Motor Corporation

  9. AUTOSTAMP - Progressive Dies

  10. AUTOSTAMP - Progressive Dies Stress Stresses Thickness FLC Forming Limit Curve FLD Forming Limit Diagram Strain Typical output at every step

  11. AUTOSTAMP - Progressive Dies

  12. Hot forming Temperature can be checked at any stage of the process PAM-STAMP2G results can be mapped on any mesh and exported to ASCII format. Results can for instance be used for structural analysis.

  13. Stretch Forming Panels Typically leading edge, engine casings, and fuselage skins Several different variations on the process, can be simulated with PS2G Stretching controls springback

  14. Tube Bending ovalisation prediction wrinkling prediction Non-circular tube capability Multi-bends/Compound bends capability

  15. Simulation of SPF under PAM-STAMP 2G • A combined solution based on Implicit and Explicit solvers • Simple K/M as special SPF material model; new model with grain growth is also available in 2009 Release. • Total flexibility to add new constitutive equation as a user-subroutine • Various type of interaction between sheet and die (friction, sliding, and sticking) • Various type of elements, solid, triangular and quads shell with mesh adaptively. • Simulation of single sheet and multiple sheets with DB • Full description of thickness and strain distribution, final shape accuracy • Forming based on a prescribed pressure profile • Predicting Pressure Cycle with full control of strain rate or stress flow with a customised stop parameter • Maximum pressure/time/ volume flow rate (machine specific) or optimum strain rate (material specific).

  16. PS2G Pre-process: SPF Simple K-m Equation with target strain rate Advanced constitutive models with grain size/grain growth are available Dedicated Pre-process macro template for the Superplastic forming process.

  17. PS2G, typical output of SPF Simulation Distance between sheet and die surface Major strains Thickness distribution Pressure Cycle with respect to max strain rate 18

  18. PS2G Post-process: SPF

  19. Outline of Presentation • PAM-STAMP 2G, Simulation of SPF and other Sheet Metal Forming processes. • Reminder of what SIM-O-SPF is about..? • Update on developments since last meeting • Proposals from Academic Partners • Actions and Timeframe 20

  20. SIM-O-SPF will provide a forum to share knowledge and experience about SPF process in general and Simulation of SPF in particular. Will identify limitations of current Simulation capabilities and recommend future developments Will create an effective partnership amongst all Members from different background (academia, commercial software and industry) Providing immediate access to well established simulation tools that are used by various parties for SPF applications in Aerospace, Rail and Automotive Introduce Simulation-based approach to SPF that would result in higher quality components, improved design, optimized manufacturing parameters and a more cost effective approach Enhance the capabilities of existing Simulation tools by further developments and diversity in applications what are the objectives..?

  21. ESI Software, organization, training, technical support and further developments Partnership with major players in the SPF community in the UK Academic Partners Technical expertise, diversity in applications, training facility, publication Publication, software and expertise, industrial support and spin off proposals Industrial Partners Financial contribution, control over the technical agenda, Safer and cost effective option to adapt new technology with direct access to a pool of expertise and resources. Very attractive financial terms (3 years discount) Contribution and benefit for Members

  22. Outline of Presentation • PAM-STAMP 2G, Simulation of SPF and other Sheet Metal Forming processes. • Reminder of what SIM-O-SPF is about..? • Update on developments with Industrial Partners • Proposals from Academic Partners • Actions and Timeframe 24

  23. Benchmark in collaboration with BAeSystems Profile of cross section Thickness distribution for fully formed sheet

  24. Predicted Pressure Cycle based on optimum strain rate Benchmark in collaboration with BAeSystems

  25. Benchmark in collaboration with BAeSystems

  26. Thickness (mm) Benchmark in collaboration with Aeromet A Cross Section A - A B B A Cross Section B - B

  27. Predicted Pressure Cycle (based on allowable max. strain rate of 0.00027s-1) X-Axis in real time (ms); so, final time = 6100s (102 minutes), max. pressure = 100psi Benchmark in collaboration with Aeromet

  28. Benchmark in collaboration with Aeromet

  29. Activities with other Industrial Partners Rolls Royce PS2G is currently used by other group in RR at Hucknall; simulation of SPF and Hot-Forming cases have been carried out. Met Mike Wallis twice and he is trying to explore available options to raise fund Doncasters I have received yesterday the CAD files for a benchmark, the Part has already been manufactured. AFRC A proposal for future collaboration and joining as T2 Member has been presented. The Centre has adopted Simulation as a major part of future activities Airbus…? Superform…!

  30. A draft of Commercial Agreement has been sent off to every Industrial Partner - very generous arrangements Feedback has been very positive and all seem to be committed and very keen on this Project All Partners are aware of the need to act ASAP, and I am chasing each one separately. It is expected that small(er) companies would be able to process the paperwork more quickly but closer follow up is needed with all Partners Current Status with Industrial Partners

  31. Outline of Presentation • PAM-STAMP 2G, Simulation of SPF and other Sheet Metal Forming processes. • Reminder of what SIM-O-SPF is about..? • Update on developments with Industrial Partners • Proposals from Academic Partners • Timeframe and actions 33

  32. Proposals from Academic Partners Swansea University Warwick University King’s College London National University of Ireland, Galway Waterford Institute of Technology University of Birmingham, Manchester University and Imperial College London …?!!

  33. Outline of Presentation • PAM-STAMP 2G, Simulation of SPF and other Sheet Metal Forming processes. • Reminder of what SIM-O-SPF is about..? • Update on developments with Industrial Partners • Proposals from Academic Partners • Actions and Timeframe 35

  34. Actions and Timeframe ESI to carry on discussions with individual Industrial Partners to refine technical programme and secure financial contribution well in time. Get the final approval from ESI on submitted Academic Proposals by 16th November 2009. Final copy of Technical Programme (with a copy of all approved Academic Projects) and Terms & Conditions to be circulated for signature early December Develop, and get an approval from ESI Management, a contingency plan in case insufficient fund was secured from Industrial Partners before the end of 2009 Agree on Training Venue (Swansea or Warwick University..?) and start preparation of computer lab by 14th December Develop a special 2-days training programme as general introduction to PS2G. To be delivered some time during the first two weeks in Jan 2010; All Partners are expected to participate. Develop customised training programme for individual Industrial Partners which will be delivered on site

  35. Thank you… Any question or suggestion…

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