DP saçlarda geri yaylanma simülasyonu-Mesut_Kaya_Coskunoz_Session15_20102010

8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010

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Presentation Outline

INTRODUCING COKUNZ METAL FORM COMPANY

STAMPING PROBLEMS OF DP STEELS

SIMULATIVE TESTS

MODELING AND SIMULATION

STAMPING EXPERIMENTS

RESULTS AND COMPARISON

FUTURE WORK


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Cokunz Metal Form Company

Mass Production Tools and Machinery Production

Tests and Analyses

MTS Durability Test SystemATOS Digitizer

Fiat Cross Car Beam

Fiat Fuel TankFord Control Arm


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Cokunz R&D Activities

Optimization with Optistruct Crash Analysis with Radioss

Forming Simulation with Autoform andHyperformPart Design with Catia

Fiat Fuel Tank BumperCokunz Design

Control ArmCokunz Design


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PUNCH

DIE

SHEET

AFTER

SPRINGBACK

REFERENCEGEOMETRY

FEMSimulation

VirtualMeasurement

DieCompansation

OK

Production

DieCompansation

OK

Measurement

FEMSimulation

No

Yes

No

Yes

SPRINGBACK COMPANSATION FLOW CHART

TOOL SETUP

STAMPED PARTGEOMETRY

Stamping Problems of DP Steels


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Simulative Tests-Tensile Test

Zwick


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FRICTIONTESTERC

Friction tester was adapted to MTS Test System and friction tests wereperformed for constant clamping forces.

0

0,02

0,04

0,06

0,08

0,1

0,12

0,14

0,16

0 10 20 30 40

mu

Clamping Press ( Mpa )

Friction Test

mu (ConstantClamping Press )

Simulative Tests-Friction Test


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Tool Mesh Parameters

Blank Mesh Parameters

Adaptivity Level

Modeling - Meshing Parameters

Altair 10.0 Training Document


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Modeling - Simulation Setup

Operations


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Modeling - Forming Simulation

Gas cylinder pressure Binder Force at 0 mmstrok

Binder force at 35 mmstrok

150 bar 460.000 N 526.000 N

Hyperform Auto Process

Gas Cylinder Pressure - Binder Force ChartTable 1


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Modeling - Springback

Symmetry Constraint (dof 1,5,6)

Dof 2,3

Dof 3

Altair 10.0 Training Document


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Die

Five parts were produced from each material lot, all parts were digitized withAtos system and comparison were made with the reference geometry.

DeviationBand

0.5mm

1mm

2mm

Lot1-150bar %16 %29 %52

Lot2-150bar %15 %28 %51

Atos Digitizing System

Binder

Punch

Scanned part

Stamped parts

Stamping Experiments

Comparison of Cad-Data withExperimental ResultsTable 2


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DeviationBand

0.5mm

1mm

2mm

Lot1-150bar %56 %84 %96

Lot2-150bar %54 %79 %92

Results and Comparision

Comparison of HyperForm Results

with Experimental Data

Springback evaluation

with Hyperview

Reference Geometry

Minus Tolerance Border

Plus Tolerance Border

Plus Tolerance

Band

Minus Tolerance

Band

Table 3 shows evaluation of the accuracies of Hyperform simulations. The results were compared with respect tothe reference part geometry. The experimental and FEM results were positioned one by one according to best fit

methodology and compared.

Table 3


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Future Work

KINEMATIC HARDENING MODEL

PRESSURE DEPENDED FRICTION COFFICIENT

INTEGRATION POINT MORE THAN 5


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THANK YOU...www.coskunoz.com.tr

Documents

DP saçlarda geri yaylanma simülasyonu-Mesut_Kaya_Coskunoz_Session15_20102010