Digital Die Design System

7/27/2019 Digital Die Design System

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3DS / Digital Die Design System3DS / Digital Die Design SystemDevelopment of basic technology for integrated forming CAE system

3DS / Digital Die Design System3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

April 14, 2006

Naomichi Mori, Inter-regional co-ordinator of 3DS project


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History of the project

1994. April Japanese partners started feasibility study1997. May Endorsed by IMS-ISC as international collaboration project

2000. January EU partners are endorsed by EU commission

2000 February Kicked off Phase I

2000. March Kick-off meeting in Isehara, Japan(Amada Metrecs)

2000. September The second inter-regional meeting in Sindelfingen, Germany (DaimlerChrysler)

2001. April The third inter-regional meeting in Tokyo and Niigata(Nissan and Tsubamex)

2001. September The fourth inter-regional meeting in Porto, Portugal (FEUP, FCTUC)

2002. April The fifth inter-regional meeting in Sendai, Japan (Tohoku University)

2002. December The sixth inter-regional meeting in Paris, France (Arcelor and Renault)

2003. March End of Phase I

2003. April Kicked off Phase II

2005. December End of Phase II

20032000 2005

Phase IFeasibility

study1994

Phase II

Japanese partners

started feasibi lity study Kicked of f Phase I

1997

3DS project wasendorsed by IMS-ISC

Kicked off Phase IIEnd of Phase IIEnd of Phase I


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Consortium composition

EU

JAPAN

SWISS

Japan

Amada Metrecs

Famotik

Nissan MotorPress Kogyo

Tsubamex

CIMPTOPS

Fukushima National college of TechnologyOsaka Institute of Technology

RIKEN

The University of Tokyo

Tokyo University of Agriculture and Technology

Tohoku University

Canada

FTI

EU

Cockerill-Sambre(Belgium)ESI (France)

Arcelor (France)

Renault Automobiles(France)

Pechiney CRV (France)

DaimlerChrysler (Germany)

Volvo Car Corporation (Sweden)

LPMTM-CNRS(France)

University of Coimbra (Portugal)

University of Porto (Portugal)

Swiss

Autoform

*This consortium composition includes all of partners from Phase I to Phase II.


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1. Quality improvement and cost reduction

2. Enhancement of quality

3. Response to processing material

changes due to weight reduction

Technological requirement in the manufacturing process fieldsTechnological requirement in the manufacturing process fields

Stamping die

Target of

3DS project

Plastic die

The above situation is same with die manufacturing of core industry

Background of the project

1. Speedy development of the high-value

added products

2. Quick delivery and cost reduction

3. Response to diversified customer needs

Change in manufacturing environmentChange in manufacturing environment


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CAD data

FEM data

Measurement data

Example of evaluating forming defects

Local shape characterization display

Press forming defect evaluation system

To realize Press forming defect evaluation

system, which is capable of aiding the

designing of a sheet-metal stamping dieand its try-out on a computer, eliminating

thus the costly and time-consuming try-out

on site as currently practiced

Goal of the project

1. To develop the definition and the

quantitative evaluation method of

geometrical forming defects

2. Constructing a set of standardbenchmark test problems

3. To develop guidelines for constructing

appropriate elasto-plastic constitutive

models

Main subjects

1. Reduction of time and cost during the

design and tryout

2. Reducing time to market3. Systematizing a system from die design to

production allows to reutilize empirical

knowledge and technique of skilled engineers

1. Reduction of time and cost during the

design and tryout

2. Reducing time to market3. Systematizing a system from die design to

production allows to reutilize empirical

knowledge and technique of skilled engineers

Effects

Outline of the project


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Current status of stamping die manufacturing

Simulation process

Part design

Die face design

Tryout process

Confirmation

Die design

NC Die processing

Tryout

Confirmation

Mass production

(Trial production)

Investigation

Empirical data base

Sheet metal formingsimulation

Investigation

Modification

Investigation

Simulated products

Formed products

Designed

products

Modification

Modification


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Technological requirements in the stamping die manufacturing

Simulation process

Part design

Die face design

Tryout process

Confirmation

Die design

NC Die processing

Tryout

Confirmation

Mass production

(Trial production)

Investigation

Sheet metal formingsimulation

Investigation

Modification

Investigation

Designed

products

Modification

Modification

Digital DATADigital DATA

Formed

products

Digital DATADigital DATA

Empirical data base


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1. Development of user-friendly methods and software for

evaluating forming defects.(WP1)

2. Evaluation and improvement of the abil ity of numerical

software to predict forming defects. (WP2)

3. Selection of appropriate physical models and their identification. (WP3)

Research and development of basic technology to construct

press forming die design support system

Outline of the research contents

Research themes:Research themes:


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WP1: Development of methods and software for evaluating forming defects)

Development of the definition and the quantitative evaluation method of geometrical forming defects

Development of the graphical software library to construct a forming defect evaluation processor system

for illustrating defined forming defects quantitatively on the computer.

Goal of the WP1:

The quantitative evaluation method of forming defects

Software called Evaluation Processor, allowing an objective comparison of CAD definition,

CAE calculations and experimental measurements on press formed parts (for benchmark test).

The processor system provided an important tool for comparing experimental and simulation results

of the benchmark problems.

Main results of the WP1


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WP2: Evaluation of the abil ity of numerical software to predict forming defects

Constructing a set of standard benchmark test problems which enabled us to evaluate

the ability of a code to predict forming defects such as wrinkle, geometrical inaccuracy due tospringback, surface deflection and so on.

In the benchmark problems, reference experimental data play a very important role and

international cooperation is indispensable to obtain well-examined worldwide standard experimental data.

Goal of the WP2:

WP2 provided a reliable experimental data base and the improvement of the available software for

predicting forming defects.



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WP3:Selection of appropriate physical models and their identification

Development of guidelines for constructing appropriate elasto-plastic constitutive

models for different steel and aluminum sheets, and realistic friction models

Development of the standard material and friction tests to find out the parameters

used in the computer simulation

Goal of the WP3:

WP3 provided a selection of material and friction models that are appropriate for predicting forming

defects by numerical simulations.



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Each research theme and its relationship

Precision improvement

(Physical model)

Precision improvement

(Physical model)

Selection of effective numerical

algorithms for implementing thephysical models into numerical code

New forming evaluationmethod

Springback Surface deflection

New forming evaluationmethod

Springback

Surface deflection

Selection of appropriate

numerical code for

predicting each forming

defect

Selection of appropriate

numerical code for

predicting each formingdefect

Selection and identification of elastoplastic and frictionmodels for the materials and tools used in the benchmarks

Standardization of input-output datafor benchmark tests

Development of a defectevaluation processor

Definition of a set of experimental benchmark tests for

evaluating numerical methods

Definition of forming defects

Standardization of object data and necessary conditions fordata acquisition

Verification of the appropriateness of the selected physicalmodels for predicting forming defects

Characterization and evaluation of forming defects

Evaluation and improvement of the ability of numericalmethods to predict forming defects

WP3/TASK2

WP1/TASK4

WP3/TASK1

WP2/TASK3WP3/TASK3

WP2/TASK2

WP2/TASK4

WP2/TASK1

WP1/TASK2

WP1/TASK1

WP1/TASK3

Carrying out the experimental benchmark tests andgeometrical measurement of the parts

3 S / S3DS / Di i l Di D i S


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Schedule,communication and

document management

Inter-regional meeting

Working groupRegional meeting

GroupWare

Researchactivities

Investigation of new evaluation method

Data server

WP3

WP2

WP1

Investigation program for formingevaluation method

Press forming Evaluation processor

Research of physical model

Benchmark tests

ICP

RCP Technical Committee

Internet

Administrative structure

3DS / Di i l Di D i S3DS / Di it l Di D i S t


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Conclusion

Management aspects:

There was always a perfect cooperation between partners and no conflict

Some friendships was established between some peoples of the consortium and

the relationship facilitate inter-regional collaboration research

We had a great pleasure to work with our European partners

From now on, the good relationship established in this project will continue

Technical aspects:

Even though we faced a lot of difficulties, 3DS project has successfully fulfilled the major part of the tasks

Quantitative evaluation method and the software called Evaluation Processor was developed

Significant number of benchmarks were successfully conducted

Numerical codes were improved in terms of fastness and accuracy

The specific mechanical tests aiming at improvement of the material representation were

successfully done

3DS / Di it l Di D i S t3DS / Di it l Di D i S t


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3DS Consortium Partners

Fourth inter-regional meeting in Porto, Portugal

3DS / Digital Die Design S stem3DS / Digital Die Design System


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3DS Consortium Partners

Fifth inter-regional meeting in Sendai, Japan

3DS / Digital Die Design System3DS / Digital Die Design System


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Finally..

I would like to take this opportunity to thank all the people of IMSfor everything done for 3DS over the years.

Especially, I would like to extend my appreciation to IMS Japan

for supporting and helping 3DS project activities.

Naomichi Mori, Inter-regional co-ordinator of 3DS

Documents

Digital Die Design System