Simulation of thermo-mechanical models for hot formed parts by numerical experiments

Abstract

The Finite-Element Analysis (FEA) is a prediction methodology that facilitates product designers produced the part design with manufacturing focused. With the similar advantages, manufacturing engineers are capable of build the first actual car model from the new production Draw Die. This approach has eliminated the requirement to manufacture the prototype model from soft tool parts and soft tool press die. However, the prediction accuracy of FEA is a major topic of research work in automotive sector's practitioners and academia as current accuracy level is anticipated at 60%. The objective of works is to assess the prediction accuracy on deformation results from mass production stamped parts. The Finite-element model is developed from the CAD data of the production tools. Subsequently, finite-element model for production tools is discretized with shell elements to avoid computation errors in the simulation process. The sheet blank material with 1.5 mm and 2.0 mm thickness is discredited by shell (2D modeling) and solid elements (3D modeling) respectively. The input parameters for the simulation model for both elements are attained from the actual setup at Press Machine and Production Tool. The analysis of deformation and plastic strain are performed for various setup parameters. Finally, the deformation characteristic such as Forming Limit Diagram (FLD) and thinning are compared for all simulated models.