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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: 2018-10-18Bibliographically approved
Sigvant, M., Falk, J. & Pilthammar, J. (2017). Experiments and FE-simulations of stretch flanging of DP-steels with different shear cut edge quality. In: Volk W. (Ed.), Journal of Physics: Conference Series. Paper presented at 36th IDDRG Conference 2017: Materials Modelling and Testing for Sheet Metal Forming, Munich. Institute of Physics Publishing, 896(1), Article ID 012101.
Open this publication in new window or tab >>Experiments and FE-simulations of stretch flanging of DP-steels with different shear cut edge quality
2017 (English)In: Journal of Physics: Conference Series / [ed] Volk W., Institute of Physics Publishing , 2017, Vol. 896, no 1, article id 012101Conference paper, Published paper (Refereed)
Abstract [en]

Dual-Phase (DP) steels are today used in the automotive industry due to its large strength to weight ratio. However, the high strength of DP-steel does have a negative impact on the general formability in sheet metal forming. Unfavourable process conditions in the press shop will, on top of this, reduce the formability of DP-steels even more. This paper addresses the problem of edge fracture in stretch flanges in sheet metal parts made of DP-steel. The experimental part involves tests of ten different DP590 and DP780 steel grades with three different shear cut qualities. The influence on the fracture strain of the sample orientation of the shear cut are also studied by facing the burr away or towards the punch and testing samples with the cut edge parallel with the rolling direction and the transverse direction. The strains are measured with an ARAMIS system in each test, together with punch displacement and punch force. All tests are then simulated with AutoFormplus R7 and the results from these simulations are compared with the experimental results in order to find the appropriate failure strain for each combination of supplier, coating, thickness and shear cut quality. © Published under licence by IOP Publishing Ltd.

Place, publisher, year, edition, pages
Institute of Physics Publishing, 2017
Keywords
Automotive industry, Finite element method, Flanges, Fracture, Fracture testing, High strength steel, Materials testing, Metal forming, Metal testing, Metals, Strain, Dual-phase steel, Fracture strain, Process condition, Punch displacement, Rolling direction, Sheet metal parts, Strength to weight ratio, Testing samples, Sheet metal
National Category
Vehicle Engineering Other Mechanical Engineering
Identifiers
urn:nbn:se:bth-15473 (URN)10.1088/1742-6596/896/1/012101 (DOI)000424196000101 ()2-s2.0-85032457673 (Scopus ID)
Conference
36th IDDRG Conference 2017: Materials Modelling and Testing for Sheet Metal Forming, Munich
Available from: 2017-11-10 Created: 2017-11-10 Last updated: 2018-07-10Bibliographically approved
Sigvant, M., Pilthammar, J., Hol, J., Wiebenga, J. H., Chezan, T., Carleer, B. & Van Den Boogaard, A. H. (2016). Friction and lubrication modeling in sheet metal forming simulations of a Volvo XC90 inner door. In: IOP Conference Series: Materials Science and Engineering. Paper presented at International Deep Drawing Research Group Conference on Challenges in Forming High-Strength Sheets, IDDRG , Linz. , 159(1), Article ID 012021.
Open this publication in new window or tab >>Friction and lubrication modeling in sheet metal forming simulations of a Volvo XC90 inner door
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2016 (English)In: IOP Conference Series: Materials Science and Engineering, 2016, Vol. 159, no 1, article id 012021Conference paper, Published paper (Refereed)
Abstract [en]

The quality of sheet metal formed parts is strongly dependent on the tribology, friction and lubrication conditions that are acting in the actual production process. Although friction is of key importance, it is currently not considered in detail in stamping simulations. This paper presents a selection of results considering friction and lubrication modeling in sheet metal forming simulations of the Volvo XC90 right rear door inner. For this purpose, the TriboForm software is used in combination with the AutoForm software. Validation of the simulation results is performed using door inner parts taken from the press line in a full-scale production run. The results demonstrate the improved prediction accuracy of stamping simulations by accounting for accurate friction and lubrication conditions, and the strong influence of friction conditions on both the part quality and the overall production stability. © Published under licence by IOP Publishing Ltd.

Keywords
Drawing (forming), Friction, Metal forming, Sheet metal, Stamping, Tribology, Friction conditions, Full-scale production, Lubrication condition, Lubrication models, Part quality, Prediction accuracy, Production process, Stamping simulations, Lubrication
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:bth-14041 (URN)10.1088/1757-899X/159/1/012021 (DOI)2-s2.0-85014714526 (Scopus ID)
Conference
International Deep Drawing Research Group Conference on Challenges in Forming High-Strength Sheets, IDDRG , Linz
Available from: 2017-03-22 Created: 2017-03-22 Last updated: 2017-11-10Bibliographically approved
Sigvant, M., Pilthammar, J., Hol, J., Wiebenga, J. H., Chezan, T., Carleer, B. & van den Boogaard, A. H. (2016). Friction and lubrication modelling in sheet metal forming simulations of the Volvo XC90 inner door. In: Cardoso, RPR Yoon, JW Dick, RE Neto, ES DeSa, JMAC Adetoro, OB (Ed.), NUMISHEET 2016: 10TH INTERNATIONAL CONFERENCE AND WORKSHOP ON NUMERICAL SIMULATION OF 3D SHEET METAL FORMING PROCESSES, PTS A AND B. Paper presented at 10th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, SEP 04-09, 2016, Bristol, ENGLAND. IOP PUBLISHING LTD, Article ID UNSP 032090.
Open this publication in new window or tab >>Friction and lubrication modelling in sheet metal forming simulations of the Volvo XC90 inner door
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2016 (English)In: NUMISHEET 2016: 10TH INTERNATIONAL CONFERENCE AND WORKSHOP ON NUMERICAL SIMULATION OF 3D SHEET METAL FORMING PROCESSES, PTS A AND B / [ed] Cardoso, RPR Yoon, JW Dick, RE Neto, ES DeSa, JMAC Adetoro, OB, IOP PUBLISHING LTD , 2016, article id UNSP 032090Conference paper, Published paper (Refereed)
Abstract [en]

The quality of sheet metal formed parts is strongly dependent on the friction and lubrication conditions that are acting in the actual production process. Although friction is of key importance, it is currently not considered in detail in stamping simulations. This paper presents project results considering friction and lubrication modelling in stamping simulations of the Volvo XC90 inner door. For this purpose, the TriboForm software is used in combination with the AutoForm software. Validation of the simulation results is performed based on door-inner parts taken from the press line in a full-scale production run. The project results demonstrate the improved prediction accuracy of stamping simulations.

Place, publisher, year, edition, pages
IOP PUBLISHING LTD, 2016
Series
Journal of Physics Conference Series, ISSN 1742-6588 ; 734
National Category
Reliability and Maintenance
Identifiers
urn:nbn:se:bth-14669 (URN)10.1088/1742-6596/734/3/032090 (DOI)000402734500095 ()
Conference
10th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, SEP 04-09, 2016, Bristol, ENGLAND
Available from: 2017-06-22 Created: 2017-06-22 Last updated: 2018-05-22Bibliographically approved
Pilthammar, J., Sigvant, M. & Kao-Walter, S. (2016). Including die and press deformations in sheet metal forming simulations. In: Cardoso, RPR Yoon, JW Dick, RE Neto, ES DeSa, JMAC Adetoro, OB (Ed.), NUMISHEET 2016: 10TH INTERNATIONAL CONFERENCE AND WORKSHOP ON NUMERICAL SIMULATION OF 3D SHEET METAL FORMING PROCESSES, PTS A AND B. Paper presented at 10th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, SEP 04-09, 2016, Bristol, ENGLAND. IOP PUBLISHING LTD, Article ID UNSP 032036.
Open this publication in new window or tab >>Including die and press deformations in sheet metal forming simulations
2016 (English)In: NUMISHEET 2016: 10TH INTERNATIONAL CONFERENCE AND WORKSHOP ON NUMERICAL SIMULATION OF 3D SHEET METAL FORMING PROCESSES, PTS A AND B / [ed] Cardoso, RPR Yoon, JW Dick, RE Neto, ES DeSa, JMAC Adetoro, OB, IOP PUBLISHING LTD , 2016, article id UNSP 032036Conference paper, Published paper (Refereed)
Abstract [en]

Structural analysis, in Abaqus, of a stamping die and subsequent morphing of the tool surfaces in AutoForm were performed to improve a sheet metal forming simulation. First, the tool surfaces of the XC90 rear door inner were scanned. They were not matching when the die was unloaded and could therefore not give any satisfying results in sheet metal forming simulations. Scanned surface geometries were then added to a structural FE-model of the complete stamping die and some influential parts of the production press. The structural FE-model was analysed with Abaqus to obtain the structural deformations of the die. The calculated surface shapes were then transferred to AutoForm where a forming simulation was performed. Results from the different sheet metal forming simulations were compared to measured draw in curves and showed a substantial increase in accuracy and ability to analyse dies in running production when the morphed surfaces were used.

Place, publisher, year, edition, pages
IOP PUBLISHING LTD, 2016
Series
Journal of Physics Conference Series, ISSN 1742-6588 ; 734
National Category
Other Mechanical Engineering
Identifiers
urn:nbn:se:bth-14668 (URN)10.1088/1742-6596/734/3/032036 (DOI)000402734500041 ()
Conference
10th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes, SEP 04-09, 2016, Bristol, ENGLAND
Available from: 2017-06-22 Created: 2017-06-22 Last updated: 2017-06-22Bibliographically approved
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Identifiers
ORCID iD: ORCID iD iconorcid.org/0000-0002-6526-976x

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