Forming Technologies Inc

1. Forming Technologies Inc

2. Contents • Introduction to CATSTAMP • Demonstration • Installation & Licensing • Support

3. Associative and regenerative formability analysis tool • Quickly identifies splitting, wrinkling and thinning • Evaluate alternate part designs and processing conditions such as pressure pads, draw beads, and binder layout • Accurately predicts feasibility of binder and addendum geometry • Substantially reduces process development time by accurately sizing blanks • Fully integrated into CATIA V5 native environment • Complete analyses in minutes

4. CATFORM vs CATSTAMP CATSTAMP includes all the functionality that is available in CATFORM plus • Curved Binder:Analyzes the forming process that starts with a curved binder that creates a curved blank. The curved blank will typically result in more material being available for the forming operation • Draw Beads:This forming condition can be used to simulate the control of material flow into the die cavity using a draw bead or a lock bead. • Safety Margin Plot:Displays the relative strain between the FLC and major strain value at each node. • Forming Displacement Plots (Magnitude, X, Y & Z):Displays the various displacement components as calculated between the part and blank. • Equivalent Stress Plots:The hypothetical stress required to deform the material by the equivalent Strain amount in a uniaxial tension test. • Equivalent Strain Plot:The hypothetical strain representing the sum of the Thickness, Major and Minor strains values in a uniaxial tension test. • Punch Force Calculation:Displays the force required to deform the material. • Point Mapping:Allows points to be mapped from the part to the blank shape

5. Demonstration CATSTAMP Analysis • Setting up the Geometry • Solving • Analyzing the Results Part Geometry Binder Geometry

6. Define Geometry • Open the file CATSTAMP.CATPart CATSTAMP requires a knitted surface model representing the top, bottom, or mid-surface of the part. If you are working with a solid model, a surface model can be extracted using CATIA functionality such as the Extract and Offset commands. • Select the External View command from the Tools menu • Select the feature called Healing.1 and select OK

7. Apply a Material • Select the Apply Material button on the Apply Material toolbar. • Select the Steel from the Library window and drag and drop it onto the part. • Select the OK button in the Library window to apply the material

8. Open a New Forming Analysis • Open a new Forming Analysis by selecting FTI Forming Analysis workbench from the Start > Analysis & Simulation pulldown. • Specify a CATSTAMP Case in the New Analysis window and select OK

9. Material Selection The standard CATIA material library does not support the material properties required to run a forming analysis, these important properties must be defined in the FTI Forming Analysis workbench. This also enables us to model different materials in different areas of the part to represent a tailor welded blank. • To define a material, select the Material Selection icon from the Forming toolbar. • Select the material CRDQ from the list • Select the OK button to accept the material type

10. Material Selection • To define the material thickness, double click on the thickness label on the graphic screen and key in a material thickness of 2 mm in the Shell Property window.

11. Tipping Most CATIA models are constructed in the assembly position. This is usually not the position the part will be formed in. For this reason, we must define the press direction prior to running the analysis. • To set the press direction (or “tipping” position), select the Tipping & Symmetry button on the Forming toolbar. • In the Tipping & Symmetry window check the Auto Tipping option to automatically calculate tip position for the part. • Select the OK button.

12. Meshing • The Mesh Parameters are automatically defined by CATSTAMP. This step is only required if the user does not want to use the recommended default mesh size. • To view the mesh parameters double click on the Part Mesh in the Specifications tree as shown below. The OCTREE Triangular Mesh window will appear with a recommended mesh size and absolute sag value defined. The size value should typically lie in the range of 10 – 40 mm. The Absolute Sag should typically be set between 0.1 – 0.5 mm.

13. Curved Binder • The CATSTAMP analysis is performed with a default flat binder. In many cases, the actual forming starts with a curved binder that creates a curved blank. The curved blank usually results in more material being available for the forming operation. This extra material has a significant effect on the results depending on the forming conditions that were applied. • To run a curved binder analysis you must have a surface representing the binder geometry. The binder shape must be developable and must be large enough to contain the developed blank shape for the model. A separate mesh must be created for the curved binder geometry. • Select the Octree Triangular Mesher icon from the forming toolbar and select the curved binder geometry called Binder Binder geometry • Select the OK button in the OCTREE Triangular Mesh window to accept the default mesh settings

14. Solving When the model set up is complete, the final step before viewing the results is meshing and solving. In CATSTAMP V5, this is combined into one step. • Select the Mesh & Compute icon from the Forming toolbar. • To start the analysis, set the drop-down box to All and press OK. This will first mesh the part and then run the solver. Once you have generated results, any changes to the input geometry or analysis setup will cause the solver and possibly the mesher to re-run when you try to reactivate a result plot. This update mechanism ensures that the analysis results are always consistent with the current model.

15. Results • Hold down the CTRL key and select each of the branches in the Specifications tree as shown. • Right click and select the Hide/Show option to hide each branch.

16. Results: Safety Zone The Safety Zone plot is a simple and quick qualitative result that can be used to evaluate the manufacturability of a part. The safety zones can be used to identity areas of splitting and wrinkling. Each color represents a different zone. The zones are listed in the plot legend. • To view the Safety Zone plot, drag and drop the Safety Zone icon from the Forming toolbar to the CATSTAMP Forming Solution Set folder

17. Results: Safety Zone To hide the binder geometry in a plot, edit the definition of the plot and turn on the part geometry filter. • Right click on the Safety Zone plot in the Specifications tree and select Safety zone object -> Definition • On the Selections tab click on Part Mesh and select OK. Failure Wrinkles

18. Multiple Forming Cases Multiple Forming Scenarios can be analyzed at once to compare the effects of different settings on the analysis results. Unique tipping positions and forming constraints can be applied to each forming case. • To add a second forming case select Stamping Case from the Insert menu. Each forming case will be listed as a unique branch in the Specifications tree. The active forming case will be underlined. To view the results from the non-active forming case, right click on the forming case and select Set As Current Case CASE #1 CASE #2 (active)

19. Tipping Each Forming Case can have a unique tipping direction. We will use the Auto Tipping command to define the tipping direction for the new Forming Case. • To set the press direction (or “tipping” position), select the Tipping & Symmetry button on the Forming toolbar. • In the Tipping & Symmetry window check the Auto Tipping option to automatically calculate tip position for the part. • Select the OK button.

20. Process Conditions: Blankholder Force To more accurately simulate the sheet metal forming process, CATSTAMP is capable of simulating process conditions such as friction, uniform or variable blankholder forces, pressure pads, draw beads or clamps. A uniform blankholder force applies a uniform edge tension to the boundary of the part during simulation. This will lead to additional stretch in the model and will help reduce wrinkling. • To apply a blankholder force to the part, select the Friction and Blankholder icon on the Forming toolbar. • Define a Medium blankholder force and select OK to apply the condition. Additionally, you can modify the friction coefficient used during the analysis to simulate special lubricants or coatings.

21. Process Conditions: Draw Bead A draw bead is a ridge constructed around a portion of a die cavity to control material flow. A groove in the mating blank holder allows the die to close. A draw bead is defined in CATSTAMP by a specifying its location and force. • To apply a draw bead to the part, select the Draw Bead icon on the Forming toolbar. • Show the folder called Drawbead Geometry located under the Links Manager.1 branch • Select the polyline on the model as shown and key in a draw bead force of 500,000 N/m2. • Select OK.

22. Solving When the model set up is complete, the final step before viewing the results is meshing and solving. In CATSTAMP V5, this is combined into one step. • Select the Mesh & Compute icon from the Forming toolbar. • To start the analysis, set the drop-down box to All and press OK. This will first mesh the part and then run the solver. Once you have generated results, any changes to the input geometry or analysis setup will cause the solver and possibly the mesher to re-run when you try to reactivate a result plot. This update mechanism ensures that the analysis results are always consistent with the current model.

23. Results: Safety Zone • To view the Safety Zone plot, drag and drop the Safety Zone icon from the Forming toolbar to the CATSTAMP Forming Solution Set folder Failure Zone Note: For this example, all points of failure occur because the thinning rate of 23% is exceeded. See thinning plot later in this exercise. Wrinkles reduced but still present

24. Results: Thickness Strain The Thickness Strain plot displays the percentage change in material thickness after the forming process. The percentage change in material thickness can be used to check for excessive thinning (negative values) or thickening (positive values). Note: typical thinning limit for steel is -23%. • To view the Thickness Strain plot, drag and drop the Thickness Strain icon from the Forming toolbar to the CATSTAMP Forming Solution Set folder • To inverse the color display on the plot, double click on the legend and check the option inverse in the Color Map Edition dialog • Move the mouse cursor over an area of the plot to view the thinning rate in that area. Minimum thinning rate of -30%

25. Results: Forming Limit Diagram The strain distribution for all the nodes on the part can be displayed on the Forming Limit Diagram (FLD). The FLD can be used to determine the forming mode and the formability of the part in a local area. • To view the Forming Limit Diagram, select the Forming Limit Diagram icon on the Forming toolbar * The FLD is an interactive diagram if the Safety Zone plot is activated and a point or group of points are selected on the FLD their location will highlight on the Safety Zone plot Thinning Rate is set to 23%

26. Results: Blank Shape CATFORM develops the optimal blank shapes for the part accounting for material stretch and deformation. • Select the Deformed Blank icon and drag and drop it to the CATFORM Forming Solution Set folder in the Specifications tree. Note: Select the Shading with Edges render style to display mesh elements on the Blank Shape

27. Results: Blank Shape • An associative surface can be created from the blank shape by selecting the Create Blank Face Feature icon on the Forming toolbar. • A non-associative surface can be created from the blank shape by selecting the Create Blank Face icon on the Forming toolbar. • A surface can also be created of the blank shape on the curved binder by selecting the Create Blank Face on binder icon on the Forming toolbar. Blank Face on Binder Part

28. CATSTAMP Licensing • To obtain a license, you must send Forming Technologies (FTI) your computers Forming ID number. • To get your Forming ID number double click on the lmformingid.txt file which can be found in your CATSTAMPV5 directory. • Send an email with your name, company name and Forming ID number to support@forming.com and a license file will be emailed back to you. • When you receive your license, place it in the C:\FTI\FTICATIAV5Rxx folder

29. Questions & Answers • Sales & Marketing sales@forming.com 905-340-2997 • Support support@forming.com 905-340-2997