dp saçlarda geri yaylanma simülasyonu-mesut_kaya_coskunoz_session15_20102010
TRANSCRIPT
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
1/16
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
2/16
Presentation Outline
INTRODUCING COKUNZ METAL FORM COMPANY
STAMPING PROBLEMS OF DP STEELS
SIMULATIVE TESTS
MODELING AND SIMULATION
STAMPING EXPERIMENTS
RESULTS AND COMPARISON
FUTURE WORK
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
3/16
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
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
4/16
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
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
5/16
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
6/16
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
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
7/16
Simulative Tests-Tensile Test
Zwick
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
8/16
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
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
9/16
Tool Mesh Parameters
Blank Mesh Parameters
Adaptivity Level
Modeling - Meshing Parameters
Altair 10.0 Training Document
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
10/16
Modeling - Simulation Setup
Operations
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
11/16
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
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
12/16
Modeling - Springback
Symmetry Constraint (dof 1,5,6)
Dof 2,3
Dof 3
Altair 10.0 Training Document
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
13/16
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
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
14/16
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
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
15/16
Future Work
KINEMATIC HARDENING MODEL
PRESSURE DEPENDED FRICTION COFFICIENT
INTEGRATION POINT MORE THAN 5
-
8/6/2019 DP salarda geri yaylanma simlasyonu-Mesut_Kaya_Coskunoz_Session15_20102010
16/16
THANK YOU...www.coskunoz.com.tr