汽车设计与维修人员培训课件成形与模拟英文版

©2012NovelisInc.SimulationandValuationformaterialandmoldNovelisBeforeSOPworkPresentedbyAnnaTong,TechnicalServiceEngineer©2012NovelisInc.WorkbeforeSOP©2012NovelisInc.Simulation-CAEworkFormingsimulation©2012NovelisInc.Software:ABAQUS–NonLinearApplicationsCatiaV5–CADPackage,PAGDataimportHyperWorks–CAD,Structural,FormabilityLS-Dyna3D–CAD,Formability,HeadImpactMScFatigue–FatigueNastran–StructuralSolverPamStamp–CAD,FormabilityAutoform–CAD,FormabilityPatran–StructuralPreandPost©2012NovelisInc.STARTAutoFormCODE?ELEMENTTYPE?LUBRICANTPAM-StampLS-DYNALUBRICANTSolidAL0700.12–0.14SemiSolidAluVS,VP490.15–0.16WetMP4040.18–0.2SolidAL0700.08–0.1SemiSolidAluVS,VP490.1–0.12WetMP4040.12–0.14SolidAL0700.05–0.06SemiSolidAluVS,VP490.07–0.09WetMP4040.1–0.12LUBRICANTLUBRICANTLUBRICANTBendingEnhancedMembraneShellSuggestedCoulombCoefficientofFrictionValuesForUseInCommonSimulationCodesPossibleModifications:C.o.F.Isreducedforhardenedsurfaces(chrome,nitrideetc),highlypolishedtoolsurfaces,EDTsurfacefinish.C.o.F.isincreasedforsofttoolsurfaces,poortoolfinish.Allsuggestedvaluesareonlyvalidforfullincrementalsolutions(thatisnotone-steporquicksolveversions).©2012NovelisInc.Materialdata■-Density■-Young’sModulus■-Poisson’sratio■-Proofstress(Rp0.2)■-Anisotropy:givenbythedirectionalityoftheyieldstresscomparedtotherollingdirection,itistherelationshipbetweenthethicknessstrainandthewidthstrain(r-value)■-Flowcurvesseenextslide■Truestress:r=(1+)■Truestrainr==ln(1+)-nvalueThestrainhardeningexponentnisdefinedastheexponentofthetruestraininthemathematicalequationrelatingthetruestresstothetruestrain.■r=K•rn©2012NovelisInc.Hardeningcurve•UseofequationstofittheexperimentalflowcurvesofmaterialClassicalequationused:Ludwickequation•Uniaxialtensiletestingonlygivessmallstrainsbeforefractureoccurs(20to30%).Inrealstampedpart,higherbi-directionalstrainsisachievedbeforefractureUseofequationstoextrapolatematerial’sbehaviourforhigherelongation•Withbi-axialtestingflowstresscurveswithhigherstrainscanbeachievedleadingtolessextrapolationoftheflowstresscurvesClassicalequationsused:ModifiedVoceandHockett-Sherby©2012NovelisInc.■Forthehardeningcurve,thisisextendedfromtheexperimentaldatatop=1■Thisisdonebymathematicallyfittingthelongitudinalrawdata(suppliedinthedatasheets)toapredefinedequationexamplesofwhichareshownbelow).ThiscanbedoneinExcelorvariouscommerciallyavailablesoftwarepackages.■Ifthe‘table’optionisnotused,thesoftwareofferspredefinedequations–Ludwik,Swiftetc.Thesearetypicallyusedforsteel.■ForAluminiumwetypicallyuseasaturationcurvesuchas‘Voce’tofittherawdatato:©2012NovelisInc.YieldSurface•Barlat(1989)–r0,r45,r90areprovidedonourstandarddatasheet–Mvaluesis8forAluminiumand5–6forsteel.•BBCAlu(2005)–r0,r45,r90&σ45,σ90areprovidedonourstandarddatasheet(σ45,σ90aretheyieldstressesintheDiagonal&Transversedirections).–Mvaluesare8forAluminiumand5–6forsteel.©2012NovelisInc.Copyright2007NovelisSwitzerlandSAFormingLimitDiagrams(FLDs)DefinitionFormingLimitDiagrams(FLD)areusedtoevaluatetheresultofaformingsimulationorastampedpartbydisplayingthelocaldistancetostrainlimits.FLDsshowthemaximumamountofstrainbeforefailurebyneckingorfractureasafunctionofthestateof2-dimensionaldeformation(majorandminorstrain).Majorstrain1Minorstrain20.000.050.100.150.200.250.300.350.400.450.50-0.20-0.15-0.10-0.050.000.050.100.150.200.250.300.350.40MinorStrainMajorStrainMean+Sigma-SigmaFLDpoints2=0:planestrain21Minorstrain:2MajorStrain:11=2:stretchforming2=0:planestrain1=-22:uniaxialtensile1=-2:deepdrawing©2012NovelisInc.FLC■TheoptiontocalculateatheoreticalFLC(Arcelor/Keeler)isnotpromotedparticularlywhenanexperimentallyderivedcurveisavailable.■Normally,thematerialmanufacturerdeterminestheFormingLimitCurvesaccordingtotheNakajimaorMarciniaktests.©2012NovelisInc.Copyright2007NovelisSwitzerlandSAFLDTypicalstrainpaths0.00.10.20.30.40.5-0.4-0.3-0.2-0.10.00.10.20.30.4Minorstrain2Majorstrain1Uniaxialtension1=-2*2Planestrain2=0Biaxialtension1=2...Deepdrawing1=-2Notfeasible©2012NovelisInc.©2012NovelisInc.Copyright2007NovelisSwitzerlandSAFLDFormingoperationOpticaldeformationmeasuringsystem©LFT03/12168Grid/stochasticcoating5sample‘sgeometrieswith3validtests©2012NovelisInc.FLDDefinitionofforminglimit,selectionofmeasuringpointMajorstrain:1=ln(l1/l0)Minorstrain:2=ln(l2/l0)©2012NovelisInc.Copyright2007NovelisSwitzerlandSAFLDAlloysforskinpanelsFormingLimitDiagram(accordingtoISO/WD12004:2004E)0.0000.0500.1000.1500.2000.2500.3000.3500.4000.4500.500-0.200-0.150-0.100-0.0500.0000.0500.1000.1500.2000.2500.3000.3500.400MinorStrainMajorStrainAc-1601.1mmAc-140PX1.1mmAc-170PX1.1mmAc-1211.0mmAA61110.93mm©2012NovelisInc.Copyright2007NovelisSwitzerlandSAFLDAlloysforinnerpanelsFormingLimitDiagram(accordingtoISO/WD12004:2004E)00.050.10.150.20.250.30.350.40.450.5-0.2-0.15-0.1-0.0500.050.10.150.20.250.30.350.4MinorStrainMajorStrainEcodal6081.1mmAA57541.2mmAA51821.2mmAc-1181.1mmAlMg5.7©2012NovelisInc.Valuation-compatibilityformoldandmaterialFLD/CGAanalysis©2012NovelisInc.Grinding-oiling-stamping■Differentetch