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Publications (10 of 13) Show all publications
Chezan, A. R., Khandeparkar, T. V., Ten Horn, C. H. L. & Sigvant, M. (2019). Accurate sheet metal forming modeling for cost effective automotive part production. In: IOP Conference Series: Materials Science and Engineering. Paper presented at 38th International Deep Drawing Research Group Annual Conference, IDDRG, Enschede; Netherlands, 3 June 2019 through 7 June 2019. Institute of Physics Publishing (1)
Open this publication in new window or tab >>Accurate sheet metal forming modeling for cost effective automotive part production
2019 (English)In: IOP Conference Series: Materials Science and Engineering, Institute of Physics Publishing , 2019, no 1Conference paper, Published paper (Refereed)
Abstract [en]

Recent implementations of accurate material and tribology models in finite element codes for sheet metal forming process development have the potential to reduce development time and the associated development costs significantly. Adoption of new models requires validated material parameters and assessments of the overall accuracy. The paper presents a study aimed at accuracy estimation by comparing strain measurements and finite element simulation results for a laboratory flat bottom hole expansion test and an industrial automotive component produced at Volvo Cars. The use of the tensile test based Tata Steel Vegter yield locus model results in accurate prediction of dimensions and plastic deformation distribution in sheet metal forming applications. © Published under licence by IOP Publishing Ltd.

Place, publisher, year, edition, pages
Institute of Physics Publishing, 2019
National Category
Other Mechanical Engineering
Identifiers
urn:nbn:se:bth-19185 (URN)10.1088/1757-899X/651/1/012007 (DOI)2-s2.0-85078223592 (Scopus ID)
Conference
38th International Deep Drawing Research Group Annual Conference, IDDRG, Enschede; Netherlands, 3 June 2019 through 7 June 2019
Note

open access

Available from: 2020-02-06 Created: 2020-02-06 Last updated: 2020-02-06Bibliographically approved
Sigvant, M., Pilthammar, J., Hol, J., Wiebenga, J. H., Chezan, T., Carleer, B. & van den Boogaard, T. (2019). Friction in sheet metal forming: Influence of surface roughness and strain rate on sheet metal forming simulation results. In: Procedia Manufacturing: . Paper presented at 18th International Conference on Sheet Metal, SHEMET, Leuven, 15 April 2019 through 17 April 2019 (pp. 512-519). Elsevier B.V.
Open this publication in new window or tab >>Friction in sheet metal forming: Influence of surface roughness and strain rate on sheet metal forming simulation results
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2019 (English)In: Procedia Manufacturing, Elsevier B.V. , 2019, p. 512-519Conference paper, Published paper (Refereed)
Abstract [en]

The quality of sheet metal formed parts is strongly dependent on the tribology and friction conditions that are acting in the actual forming process. These friction conditions are then dependent on the tribology system, i.e. the applied sheet material, coating and tooling material, the lubrication and process conditions. Although friction is of key importance, it is currently not considered in detail in sheet metal forming simulations. The current industrial standard is to use a constant (Coulomb) coefficient of friction, which limits the overall simulation accuracy. Since a few years, back there is an ongoing collaboration on friction modelling between Volvo Cars, Tata Steel, TriboForm Engineering, AutoForm Engineering and the University of Twente. In previous papers by the authors, results from lab scale studies and studies of body parts at Volvo Cars, both parts in early tryout for new car models as well as parts in production have been presented. However, the introduction of a new friction model in the sheet metal forming simulations forces the user to gain knowledge about accurate values for new input parameters and question current modeling assumptions. This paper presents results from studies on the influence on the sheet metal forming simulation results from stamping die surface roughness and introduction of strain rate sensitivity in the sheet material model. The study will use a FE-model of a part presented in previous papers. © 2019 The Authors. Published by Elsevier B.V.

Place, publisher, year, edition, pages
Elsevier B.V., 2019
Keywords
Friction modeling, Material modeling, Sheet metal forming simulations, Tribology
National Category
Tribology (Interacting Surfaces including Friction, Lubrication and Wear)
Identifiers
urn:nbn:se:bth-19057 (URN)10.1016/j.promfg.2019.02.169 (DOI)2-s2.0-85076176442 (Scopus ID)
Conference
18th International Conference on Sheet Metal, SHEMET, Leuven, 15 April 2019 through 17 April 2019
Note

Open access

Available from: 2019-12-27 Created: 2019-12-27 Last updated: 2019-12-27Bibliographically approved
Barlo, A., Sigvant, M. & Endelt, B. (2019). On the Failure Prediction of Dual-Phase Steel and Aluminium Alloys Exposed to Combined Tension and Bending. In: IOP Conference Series: Materials Science and Engineering. Paper presented at 38th International Deep Drawing Research Group Annual Conference, IDDRG, Enschede; Netherlands, 3 June 2019 through 7 June 2019. Institute of Physics Publishing, 651(1), Article ID 012030.
Open this publication in new window or tab >>On the Failure Prediction of Dual-Phase Steel and Aluminium Alloys Exposed to Combined Tension and Bending
2019 (English)In: IOP Conference Series: Materials Science and Engineering, Institute of Physics Publishing , 2019, Vol. 651, no 1, article id 012030Conference paper, Published paper (Refereed)
Abstract [en]

The interest in accurate prediction of failure of sheet metals in the automotive industry has increased significantly over the last two decades. This paper aims to evaluate two failure prediction approaches implemented in the commercial Finite Element code AutoFormplus R7.04; (i) the standard Forming Limit Diagram (FLD), and (ii) the Non-linear Forming Limit Diagram. The evaluation will be testing the two approaches accuracy on predicting failure of both an AA6016 aluminium alloy and a CR440Y780T-DP dual-phase steel alloy specimen exposed to combined tension and bending. Based on the findings of this study, it is concluded that neither of the evaluated approaches is able to accurately predict failure in both cases presented. © Published under licence by IOP Publishing Ltd.

Place, publisher, year, edition, pages
Institute of Physics Publishing, 2019
National Category
Other Mechanical Engineering
Identifiers
urn:nbn:se:bth-19184 (URN)10.1088/1757-899X/651/1/012030 (DOI)2-s2.0-85078300914 (Scopus ID)
Conference
38th International Deep Drawing Research Group Annual Conference, IDDRG, Enschede; Netherlands, 3 June 2019 through 7 June 2019
Note

open access

Available from: 2020-02-06 Created: 2020-02-06 Last updated: 2020-02-06Bibliographically approved
Sigvant, M., Pilthammar, J., Hol, J., Wiebenga, J. H., Chezan, T., Carleer, B. & Van Den Boogaard, A. H. (2018). Friction in Sheet Metal Forming: Forming Simulations of Dies in Try-Out. In: Journal of Physics: Conference Series. Paper presented at NUMISHEET 2018: 11th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, 30 July 2018 through 3 August 2018. Institute of Physics Publishing (1)
Open this publication in new window or tab >>Friction in Sheet Metal Forming: Forming Simulations of Dies in Try-Out
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2018 (English)In: Journal of Physics: Conference Series, Institute of Physics Publishing , 2018, no 1Conference paper, Published paper (Refereed)
Abstract [en]

The quality of sheet metal formed parts is strongly dependent on the tribology and friction conditions that are acting in the actual forming process. This paper focuses on the tribology conditions during early try-out of dies for new car models. The motivation for the study is that the majority of the forming simulations at Volvo Cars are performed to secure the die try-out, i.e. solve as many problems as possible in forming simulations before the final design of the die and milling of the casting. In the current study, three closure parts for the new Volvo V60 model have been analysed with both Coulomb and TriboForm friction models. The simulation results from the different friction models are compared using thickness measurements of real parts, and 3D geometry scanning data of the parts. Results show the improved prediction capability of forming simulations when using the TriboForm friction model, demonstrating the ability to accurately describe try-out conditions in sheet metal forming simulations. © 2018 Institute of Physics Publishing. All rights reserved.

Place, publisher, year, edition, pages
Institute of Physics Publishing, 2018
Keywords
Casting, Dies, Friction, Metal forming, Metals, Model automobiles, Numerical models, Thickness measurement, Tribology, 3D geometry, Car models, Forming simulations, Friction conditions, Friction modeling, Friction models, Prediction capability, Scanning data, Sheet metal
National Category
Other Mechanical Engineering
Identifiers
urn:nbn:se:bth-16979 (URN)10.1088/1742-6596/1063/1/012134 (DOI)2-s2.0-85051844252 (Scopus ID)
Conference
NUMISHEET 2018: 11th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, 30 July 2018 through 3 August 2018
Note

Open Access

Available from: 2018-09-06 Created: 2018-09-06 Last updated: 2018-09-06Bibliographically approved
Sigvant, M., Pilthammar, J., Hol, J., Wiebenga, J. H., Chezan, T., Carleer, B. & Van Den Boogaard, A. H. (2018). Friction in Sheet Metal Forming Simulations: Modelling of New Sheet Metal Coatings and Lubricants. In: IOP Conference Series: Materials Science and Engineering. Paper presented at 37th International Deep Drawing Research Group Conference - Forming of High Performance Sheet Materials and Components, IDDRG 2018, 3 June 2018 through 7 June 2018, Waterloo, Canada. Institute of Physics Publishing, 418(1), Article ID 012093.
Open this publication in new window or tab >>Friction in Sheet Metal Forming Simulations: Modelling of New Sheet Metal Coatings and Lubricants
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2018 (English)In: IOP Conference Series: Materials Science and Engineering, Institute of Physics Publishing , 2018, Vol. 418, no 1, article id 012093Conference paper, Published paper (Refereed)
Abstract [en]

The quality of sheet metal formed parts is strongly dependent on the tribology and friction conditions that are acting in the actual forming process. These friction conditions are then dependent on the tribology system, i.e. the applied sheet material, coating and tooling material, the lubrication and process conditions. Although friction is of key importance, it is currently not considered in detail in sheet metal forming simulations. The current industrial standard is to use a constant (Coulomb) coefficient of friction, which limits the overall simulation accuracy. Since a few years back there is an ongoing collaboration on friction modelling between Volvo Cars, Tata Steel, TriboForm Engineering, AutoForm Engineering and the University of Twente. In previous papers by the authors, results from lab scale studies and studies of a door-inner part in Volvo Cars production have been presented. This paper focuses on the tribology conditions during early tryout of dies for new car models with an emphasis on the effect of the usage of new steel material coatings and lubricants on forming results. The motivation for the study is that the majority of the forming simulations at Volvo Cars are performed to secure the die tryout, i.e. solve as many problems as possible in forming simulations before the final design of the die and milling of the casting. In the current study, three closure parts for the new Volvo V60 model have been analysed with both Coulomb and TriboForm friction models. The simulation results from the different friction models are compared using thickness measurements of real parts, and 3D geometry scanning data of the parts. Results show the improved prediction accuracy of forming simulations when using the TriboForm friction model, demonstrating the ability to account for the effect of new sheet metal coatings and lubricants in sheet metal forming simulations. © Published under licence by IOP Publishing Ltd.

Place, publisher, year, edition, pages
Institute of Physics Publishing, 2018
Series
IOP Conference Series: Materials Science and Engineering, ISSN 1757-8981 ; 1
Keywords
Casting, Deep drawing, Drawing (forming), Friction, Metal coatings, Metals, Model automobiles, Thickness measurement, Tribology, Coefficient of frictions, Forming simulations, Friction conditions, Friction modelling, Industrial standards, Prediction accuracy, Simulation accuracy, University of Twente, Sheet metal
National Category
Tribology (Interacting Surfaces including Friction, Lubrication and Wear)
Identifiers
urn:nbn:se:bth-17145 (URN)10.1088/1757-899X/418/1/012093 (DOI)2-s2.0-85054275977 (Scopus ID)
Conference
37th International Deep Drawing Research Group Conference - Forming of High Performance Sheet Materials and Components, IDDRG 2018, 3 June 2018 through 7 June 2018, Waterloo, Canada
Note

open access

Available from: 2018-10-19 Created: 2018-10-19 Last updated: 2018-10-19Bibliographically approved
Pilthammar, J., Sigvant, M. & Kao-Walter, S. (2018). Introduction of elastic die deformations in sheet metal forming simulations. International Journal of Solids and Structures, 151(S1), 76-90
Open this publication in new window or tab >>Introduction of elastic die deformations in sheet metal forming simulations
2018 (English)In: International Journal of Solids and Structures, ISSN 0020-7683, E-ISSN 1879-2146, Vol. 151, no S1, p. 76-90Article in journal (Refereed) Published
Abstract [en]

Simulations of sheet metal forming (SMF) with finite element models (FE-models) for stamped parts in the car industry are useful for detecting and solving forming problems. However, there are several issues that are challenging to analyze. Virtual tryout and analyzes of stamping dies in running production are two important cases where many of these challenging issues are present. Elastic deformations of dies and press lines and a physically based friction model is often missing when these types of cases are analyzed. To address this, this research aims to develop a method wherein the results of two separate FE-models are combined to enable SMF simulations with the inclusion of elastic tool and press deformations. The two FE-models are one SMF model with two-dimensional (2D) rigid tool surfaces and one structural model of the die and press. The structural model can predict surface shapes and pressure distributions for a loaded stamping die. It can also visualize relatively large and unexpected deformations of the die structure. The recommended method of transferring the deformations from the structural model to the 2D surfaces is through an FE technique called submodeling. The subsequent SMF simulations show that the method for calculating and using the deformed surfaces together with the TriboForm friction model yields a result that matches measured draw-in and strains. It is verified that the ability to virtually deform a die and include the resulting geometry in forming simulations is of high importance. It can be used for the virtual tryout and optimization of new dies or analyses of existing dies in running production. It is suggested that future research focus on a more efficient and automated workflow. More experimental data and simulations are also needed to verify the assumptions made for the simulation models. This will enable the method to be adopted in a reliable way for standard SMF simulations. © 2017.

Place, publisher, year, edition, pages
Elsevier Ltd, 2018
Keywords
Elastic tooling, Friction, Sheet metal forming, Structural analysis, Surface compensation, Automotive industry, Computer supported cooperative work, Deformation, Dies, Metal forming, Presses (machine tools), Sheet metal, Stamping, Tribology, Automated workflow, Forming simulations, Friction modeling, Physically based, Research focus, Structural modeling, Two Dimensional (2 D), Finite element method
National Category
Materials Engineering
Identifiers
urn:nbn:se:bth-14475 (URN)10.1016/j.ijsolstr.2017.05.009 (DOI)000447577700007 ()2-s2.0-85019444887 (Scopus ID)
Note

The authors are grateful for the financial support from Volvo Cars and wishes to thank Tata Steel, AutoForm Engineering, and TriboForm Engineering for valuable cooperation and support. The authors also wish to express their appreciation of their management team at Volvo Cars and Mats Walter, Head of Mechanical Engineering Department at Blekinge Institute of Technology, for enabling an eminent cooperation.

Available from: 2017-06-13 Created: 2017-06-13 Last updated: 2018-11-01Bibliographically approved
Tatipala, S., Pilthammar, J., Sigvant, M., Wall, J. & Johansson, C. (2018). Introductory study of sheet metal forming simulations to evaluate process robustness. In: IOP Conference Series: Materials Science and Engineering: . Paper presented at 37th IDDRG Conference - Forming of High Performance Sheet Materials and Components, Waterloo, Canada.. Institute of Physics Publishing (IOPP), 418, Article ID 012111.
Open this publication in new window or tab >>Introductory study of sheet metal forming simulations to evaluate process robustness
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2018 (English)In: IOP Conference Series: Materials Science and Engineering, Institute of Physics Publishing (IOPP), 2018, Vol. 418, article id 012111Conference paper, Published paper (Refereed)
Abstract [en]

The ability to control quality of a part is gaining increased importance with desires to achieve zero-defect manufacturing. Two significant factors affecting process robustness in production of deep drawn automotive parts are variations in material properties of the blanks and the tribology conditions of the process. It is imperative to understand how these factors influence the forming process in order to control the quality of a formed part. This paper presents a preliminary investigation on the front door inner of a Volvo XC90 using a simulation-based approach. The simulations investigate how variation of material and lubrication properties affect the numerical predictions of part quality. To create a realistic lubrication profile in simulations, data of pre-lube lubrication amount, which is measured from the blanking line, is used. Friction models with localized friction conditions are created using TriboForm and is incorporated into the simulations. Finally, the Autoform-Sigmaplus software module is used to create and vary parameters related to material and lubrication properties within a user defined range. On comparing and analysing the numerical investigation results, it is observed that a correlation between the lubrication profile and the predicted part quality exists. However, variation in material properties seems to have a low influence on the predicted part quality. The paper concludes by discussing the relevance of such investigations for improved part quality and proposing suggestions for future work.

Place, publisher, year, edition, pages
Institute of Physics Publishing (IOPP), 2018
Series
IOP Conference Series: Materials Science and Engineering, ISSN 1757-8981
Keywords
Sheet Metal Forming, Friction Modelling, Process Robustness, Zero Defect Manufacturing, Industry 4.0, Digitization, Production Engineering.
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:bth-16613 (URN)10.1088/1757-899X/418/1/012111 (DOI)
Conference
37th IDDRG Conference - Forming of High Performance Sheet Materials and Components, Waterloo, Canada.
Projects
Model Driven Development and Decision Support
Funder
Knowledge Foundation
Note

open access

Available from: 2018-06-23 Created: 2018-06-23 Last updated: 2019-11-25Bibliographically approved
Sigvant, M., Pilthammar, J., Tatipala, S. & Andreasson, E. (2018). SMART STAMPING: IMPROVED QUALITY IN STAMPING BY MODEL DRIVEN CONTROL. In: : . Paper presented at 11th Forming Technology Forum, Zurich, Switzerland (pp. 59-62).
Open this publication in new window or tab >>SMART STAMPING: IMPROVED QUALITY IN STAMPING BY MODEL DRIVEN CONTROL
2018 (English)Conference paper, Published paper (Refereed)
Abstract [en]

Sheet Metal Forming is a very complex manufacturing process with a number of non-linearities, e.g. large deformations, localisation, elastic-plastic materials, pressure and velocity dependant friction conditions and structural deficiencies in the die and press, present and interacting simultaneously. This leads to disturbances in running production that results in production waste, e.g. down time for the press line and cost for rework and scrapping of parts. These production problems are also hard to understandand solve based on experience and analytical models due to the presence of several non-linearities. An alternative is to try to solve these problems proactively before they occur. This could be done with model based control by creating a digital twin of the die-set and the press line. Therefore, a virtual production process is developed to be able to use as knowledge building and as engineering tool during development, manufacturing, issue resolution and optimization. In this paper presents the authors ideas and plans for research and other activities within the area of model based control of sheet metal forming.

Keywords
Industry 4.0, Model Driven Control, Sheet Metal Forming Simulations, Material modelling, Friction Modelling, Elastic stamping dies.
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:bth-18935 (URN)
Conference
11th Forming Technology Forum, Zurich, Switzerland
Funder
Knowledge Foundation
Available from: 2019-11-19 Created: 2019-11-19 Last updated: 2019-11-20Bibliographically approved
Chezan, T., Khandeparkar, T., Van Beeck, J. & Sigvant, M. (2018). Strategies for increasing the accuracy of sheet metal forming finite element models. In: Journal of Physics: Conference Series. Paper presented at NUMISHEET 2018: 11th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, Tokyo. Institute of Physics Publishing (1)
Open this publication in new window or tab >>Strategies for increasing the accuracy of sheet metal forming finite element models
2018 (English)In: Journal of Physics: Conference Series, Institute of Physics Publishing , 2018, no 1Conference paper, Published paper (Refereed)
Abstract [en]

Accurate modelling of sheet metal forming can contribute significantly to reduction of lead time and development costs in manufacturing industries. The current way to improve the finite element model accuracy is to combine advanced constitutive material models and advanced tribological models. For model validation purposes the geometry of the forming tools needs to be updated and the most relevant parameters of the forming press needs to be incorporated. The addition of a simple and easier to control model test can offer additional information on difficult to characterize parameters of the industrial process. The industrial validation case presented in this paper demonstrates that the Tata Steel constitutive material model has similar prediction capability as the state of the art material model used at Volvo Cars for regular process development for automotive parts production. In both industrial and model tests the tribological system appears to affect significantly the overall model accuracy. The model tests suggests that further work is needed in order to improve the tribological model description at high contact pressure and high strain levels. © 2018 Institute of Physics Publishing. All rights reserved.

Place, publisher, year, edition, pages
Institute of Physics Publishing, 2018
Keywords
Metal forming, Metals, Numerical models, Sheet metal, Tribology, Constitutive materials, High contact pressures, Industrial processs, Industrial validation, Manufacturing industries, Prediction capability, Tribological models, Tribological systems, Finite element method
National Category
Other Mechanical Engineering
Identifiers
urn:nbn:se:bth-16977 (URN)10.1088/1742-6596/1063/1/012138 (DOI)2-s2.0-85051859032 (Scopus ID)
Conference
NUMISHEET 2018: 11th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, Tokyo
Note

open access

Available from: 2018-09-06 Created: 2018-09-06 Last updated: 2018-09-06Bibliographically approved
Pilthammar, J., Sigvant, M., Hansson, M., Pálsson, E. & Rutgersson, W. (2017). Characterizing the Elastic Behaviour of a Press Table throughTopology Optimization. In: Volk W. (Ed.), Journal of Physics: Conference Series: . Paper presented at 36th IDDRG-2017 - MATERIALS MODELLING AND TESTING FOR SHEET METAL FORMING, MUNICH. Institute of Physics Publishing (IOPP), 896, Article ID 012101.
Open this publication in new window or tab >>Characterizing the Elastic Behaviour of a Press Table throughTopology Optimization
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2017 (English)In: Journal of Physics: Conference Series / [ed] Volk W., Institute of Physics Publishing (IOPP), 2017, Vol. 896, article id 012101Conference paper, Published paper (Refereed)
Abstract [en]

Sheet metal forming in the car industry is a highly competitive area. The use ofdigital techniques and numerical methods are therefore of high interest for reduced costs andlead times. One method for reducing the try-out phase is virtual rework of die surfaces. Thevirtual rework is based on Finite Element (FE) simulations and can reduce and support manualrework. The elastic behaviour of dies and presses must be represented in a reliable way in FEmodelsto be able to perform virtual rework. CAD-models exists for nearly all dies today, butnot for press lines. A full geometrical representation of presses will also yield very large FEmodels.This paper will discuss and demonstrate a strategy for measuring and characterizing apress table for inclusion in FE-models. The measurements of the elastic press deformations iscarried out with force transducers and an ARAMIS 3D optical measurement system. The presstable is then inverse modelled by topology optimization using the recorded results as boundaryconditions. Finally, the press table is coupled with a FE-model of a die to demonstrate itsinfluence on the deformations. This indicates the importance of having a reliable representationof the press deformations during virtual rework.

Place, publisher, year, edition, pages
Institute of Physics Publishing (IOPP), 2017
Keywords
Automotive industry, Finite element method, Flanges, Fracture, Fracture testing, High strength steel, Materials testing, Metal forming, Metal testing, Metals, Strain
National Category
Applied Mechanics
Identifiers
urn:nbn:se:bth-15394 (URN)10.1088/1742-6596/896/1/012068 (DOI)000424196000068 ()
Conference
36th IDDRG-2017 - MATERIALS MODELLING AND TESTING FOR SHEET METAL FORMING, MUNICH
Funder
VINNOVA, 2016-03324
Note

open access

Available from: 2017-10-30 Created: 2017-10-30 Last updated: 2018-02-22Bibliographically approved
Organisations
Identifiers
ORCID iD: ORCID iD iconorcid.org/0000-0002-7730-506x

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