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KASHIF ASHHAR ARSALAN ZAHEER M. FAYZAN SYED WAQAS ALI (031) (032) (059) (060)
OBJECTIVE
APPLICATION OF NUMERICAL MODELING AND SIMULATION IN DESIGNING OF SHEET METAL DIES
INTRODUCTION
Flow chart of process planning and die design in traditional CAD environment
PART
MATERIAL
SACE 120 CR-DDQ-AL (JISG3314) (ASTM A 463)
THICKNESS
0.5 mm
PHASE III
MODELING & SIMULATION
One step Analysis
To conclude simply whether a product as designed is formable with ease, & if not, to identify areas on the geometry that lead to formability issues
Starting Final product geometry only with: Sheet Thickness Material Specifications Setting Parameters Die Tip Lubrication Edge Restraint Conditions
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INCREMENTAL ANALYSIS
A Full process model that simulates the forming stages as accurately as possible in logical order from blank holder closing to final flanging. With Capabilities to Analyze: Initial Deflection of Sheet due to gravity Blank holder Closing First Draws and Restrikes Cutting Operations Sheet Repositioning Flanging and Springback Hydro-Mechanical processes for Sheets and Tubes
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FIRST CONCEPT
Boundary Fill(brown),Binder(reddish brown) and Addendum ( green) created with Autoform Die Designer
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PRESS TONNAGE
CALCULATIONS:
PUNCH :
DIE
From graph: Punch force = 300kN By rule of thumb: (300kN)(2.5) = 750kN = 75tonn(approx) BLANK HOLDER: From graph: blank holding force = 120kN By rule of thumb: (120kN)(2.5) = 300kN = 30tonn(approx) PRESS TONNAGE; Press tonnage = punch force + blank holding force = 75tonn + 30tonn = 105tonn
PUNCH BLANK HOLDER
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INCREMENTAL ANALYSIS
SECOND CONCEPT
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Location of Wrinkles
Planar/Flat areas Curved areas Areas under binder
Threshold value
0.001 0.02 0.05
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DIE
BLANK HOLDER
PUNCH
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CAD MODELING
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EMBEDDING/NESTING
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AREAS COVERED
Project Scheduling. Study the Sheet Metal Forming Processes and its
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characteristics. Study Forming and Drawing Dies. Learn CAD/CAM/CAE programs (PRO-E, AUTOFORM). Designing of Draw die using AUTOFORM and PRO/E. Process Simulation using AUTOFORM. Optimize process parameters using software. Material/Cost optimization (Blank calculation and Embedding/Nesting). Manufacturing of Designed die(Scaled) using CAM techniques. PROJECT GROUP #12 Report writing.
THANK YOU
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