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  • 1.
    Pilthammar, Johan
    et al.
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Sigvant, Mats
    Volvo Cars, SWE.
    Kao-Walter, Sharon
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Including die and press deformations in sheet metal forming simulations2016In: 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 (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.

  • 2.
    Pilthammar, Johan
    et al.
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Sigvant, Mats
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Kao-Walter, Sharon
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Introduction of elastic die deformations in sheet metal forming simulations2018In: International Journal of Solids and Structures, ISSN 0020-7683, E-ISSN 1879-2146, Vol. 151, no S1, p. 76-90Article in journal (Refereed)
    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.

  • 3.
    Sigvant, M.
    et al.
    Volvo Cars, SWE.
    Pilthammar, Johan
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Hol, J.
    TriboForm Engn, NLD.
    Wiebenga, J. H.
    TriboForm Engn, NLD.
    Chezan, T.
    Tata Steel, NLD.
    Carleer, B.
    AutoForm Engn, DEU.
    van den Boogaard, A. H.
    Univ Twente, NLD.
    Friction and lubrication modelling in sheet metal forming simulations of the Volvo XC90 inner door2016In: 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 (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.

  • 4.
    Sigvant, Mats
    et al.
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Falk, Johannes
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Pilthammar, Johan
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Experiments and FE-simulations of stretch flanging of DP-steels with different shear cut edge quality2017In: Journal of Physics: Conference Series / [ed] Volk W., Institute of Physics Publishing , 2017, Vol. 896, no 1, article id 012101Conference 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.

  • 5.
    Sigvant, Mats
    et al.
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Pilthammar, Johan
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Hol, J.
    TriboForm Engineering, NLD.
    Wiebenga, J. H.
    TriboForm Engineering, NLD.
    Chezan, T.
    Tata Steel, NLD.
    Carleer, B.
    AutoForm Engineering, DEU.
    Van Den Boogaard, A. H.
    University of Twente, NLD.
    Friction in Sheet Metal Forming Simulations: Modelling of New Sheet Metal Coatings and Lubricants2018In: IOP Conference Series: Materials Science and Engineering, Institute of Physics Publishing , 2018, Vol. 418, no 1, article id 012093Conference 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.

  • 6.
    Sigvant, Mats
    et al.
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Pilthammar, Johan
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Hol, J.
    TriboForm Engineering, NLD.
    Wiebenga, J. H.
    TriboForm Engineering, NLD.
    Chezan, Toni
    Tata Steel, NLD.
    Carleer, Bart
    AutoForm Engineering Deutschland GmbH, DEU.
    Van Den Boogaard, A. H.
    University of Twente, NLD.
    Friction in Sheet Metal Forming: Forming Simulations of Dies in Try-Out2018In: Journal of Physics: Conference Series, Institute of Physics Publishing , 2018, no 1Conference 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.

  • 7.
    Sigvant, Mats
    et al.
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Pilthammar, Johan
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Hol, Jeroen
    TriboForm Engineering, NLD.
    Wiebenga, J. H.
    TriboForm Engineering, NLD.
    Chezan, T.
    Tata Steel, NLD.
    Carleer, Bart
    AutoForm Engineering, DEU.
    Van Den Boogaard, A. H.
    University of Twente, NLD.
    Friction and lubrication modeling in sheet metal forming simulations of a Volvo XC90 inner door2016In: IOP Conference Series: Materials Science and Engineering, 2016, Vol. 159, no 1, article id 012021Conference 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.

  • 8.
    Tatipala, Sravan
    et al.
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Pilthammar, Johan
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering. Volvo Cars.
    Sigvant, Mats
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering. Volvo Cars.
    Wall, Johan
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Johansson, Christian
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Introductory study of sheet metal forming simulations to evaluate process robustness2018In: IOP Conference Series: Materials Science and Engineering, Institute of Physics Publishing (IOPP), 2018, Vol. 418, article id 012111Conference 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.

1 - 8 of 8
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