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Solutions Available for Body Engineering -Summary
Virtual Manufacturing
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Task: Functional Design in a Multi-
Material Mix that Fulfills Specification
2
Sheet Aluminum
Cast Aluminum
Aluminum Sections
Hot Formed Steel
Cold Formed Steel
http://boronextrication.com/2011/08/2012-audi-a6-body-structure/
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General Trends in the
Automotive Manufacturing Industry
3
Light weight
Mixed materials for functional design (Steel, Al, Mg, CarbonFiber), New Joining and Multi-Domain Optimization to validateperformance.
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Market Trends in Steel
www.carbodydesign.com
4
HS Steel
Standard Steels
UHS Steel
Hot Formed Steel
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Trends for Forming Processes of
Light Metals
5
Krajewski,
GM, Body &
Assembly
Congress
Troy 2011
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Market Trends in Aluminum
6
http://boronextrication.com/tag/body-structure/
Cast aluminum 44%
Aluminum sheet metal 28%
Aluminum sections 17%
Steel 8%
Other materials 3%
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Advancement in VehicleStructures & Safety
Materials Optimization for BodyEngineering
Body EngineeringDigital
Optimization
Manufacturing Engineering
Those are the Engineering Disciplines
Behind
7
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This is the Job to be Done
Virtual Prototyping means reducing tests and
physical prototypes with virtual test and prototypes.
This saves the cost for the physical try-out. Also
the time it takes to do the try-out is eliminated
The mandatory condition is the ability to deliver results good enough to
reliably replace the physical tests, in a time frame significantly shorter than
physical try-out would be
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About ESI
9
Provider of Virtual Prototyping for the Industrial World
ESI is a world leading software editor for the numerical simulation of prototype
and manufacturing process engineering in applied mechanics
9
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Advancement in VehicleStructures & Safety
Materials Optimization for BodyEngineering
Body EngineeringDigital
Optimization
Manufacturing Engineering
ESI Covers Most Aspects of Body &
Assembly
10
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Crash &
Safety
Stiffness &
Strength
NVH &
DurabilityAcoustics
Drivability
Comfort
ESI Virtual Prototyping
Multi-Domain performance engineering solutions
Including the coupling effects between domains andmechanical impact of manufacturing processes
Supported by a unified Visual Environment Platform, designed
to enable multi-task automation and support Engineering
Workflow management and collaborative Engineering.
Stamping Assembly
Virtual Manufacturing
8/10/2019 17 Solutions Available For Body Engineering.pdf
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PAM-STAMP 2G:Full chain simulation with hemming assembly
PAM-DIEMAKER
for CATIA V5
Tool design
Virtual
Performance
SolutionCrash, Strength,
NVH, Durability
AssemblyForming Restrike Flanging HemmingSpringback Springback Springback Springback
Less hardware prototypes,
optimized safety marginOptimized production time
& tooling costs
Tool milling
Requirements on:
- Geometry?
-Cosmetic Defect?
Requirements on:
-Material, thickness?
End-to-End Virtual Prototyping
of a Stamped Component
12
Full chain simulation under Visual-Environment,
in early design phase
Requirements on:
- Geometry?
-Cosmetic Defect?
-Material, Thickness?
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End-to-End Virtual Prototyping
of a Hot Formed B-pillar
Full chain simulation under Visual-Environment,
in early design phase
Tool milling
PAM-STAMP 2G
Fast Hotformingwith metallurgy
PAM-DIEMAKER
for CATIA v5Quick tool design
Material
Thk, ,
% of Martensite
VPSCrash (including
spot welds rupture),
Strength, NVH, Durability
13
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End-to-End Virtual Prototyping
of a Composite B-pillar
14
Draping and RTM simulation withPAM-RTM
Lay-up
+ material
Lay-up strategy definedIn CATIA CPD or SIEMENS FiberSim
E/E0=AE*exp(BE/x)
Draping and
Porosity
affect
Mechanicalproperties
s/s0=AT*exp(BT/x)
Structural analysis with
Virtual Performance Solution
Part designchange
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Advancement in VehicleStructures & Safety
Materials Optimization for BodyEngineering
Body EngineeringDigitalOptimization
Manufacturing Engineering
Those are the Engineering Disciplines
Behind
15
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Die Face Design & Early feasibility based on geometry
Cold precision forming
Standard processes
Advanced springback for advanced materials
Class A buy-off including all following operations
Cosmetic defects
Hot forming
Casting
Materials Optimization Covers the
Following
16
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Parts Covered
17
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Time reductionEarly evaluation of manufacturing ability
Reduction in the development times
Reduction of the try-out times
Quick response to needed modifications
Cost reductionCheaper products
Reduction of the die costs
Press down sizing
Increase of reliability
Increase of product qualityOptimal selection of the work piece material
Production of more complicated parts
Know-how accumulation for new materials
Press repeatability
Benefits of Materials Optimization
with Virtual Sheet Metal Forming
Bidding and
Planning
Die Face
Design and
Validation
Precision
Forming
Cold and Hot
Altan 201218
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EARLY FEASIBILITY
Sheet Metal Forming
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Only a few parts will remain mild steel
Complex technology - presented in a simple and accessible manner
From feasibility over precision forming to millingone model based ongeometry
Standard forming operations and compensation will go into early feasibility
Springback / precision needs to be as good as humanly possible
Robustness is interesting in case the major variables are matched
Major Trends in Sheet Metal
Forming
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Die Face Design Based on Mesh
22
Die Face Design Next GenerationSwitch from Mesh
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Die Face Design Based on
Geometry
23
.to Geometry Approach - Design is Based on Geometry!
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New Proposed Work Flow
for Die Design
24
The conventional workflow is shown at the top and the new proposed workflow
based on CATIA V5 / Visual Environment is represented belowclearly
showing the potential time savings
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Die Face Design in CATIA Die
Maker - 15 to 20 Min
25
~ 10 minutesPart preparation Blankholder design ~ 1 minutes
Addendum design ~ 5 minutesExport ~ 1 minutes
http://images.google.nl/imgres?imgurl=http://www.digizelgrafix.com/portfolio/images/lineart/stopwatch-bw.jpg&imgrefurl=http://www.digizelgrafix.com/portfolio/portfolio_lineart.html&usg=__EAiSrEAyFt92ozshRJX8sapHAXk=&h=400&w=325&sz=40&hl=nl&start=50&tbnid=vVzNTYyMALz9IM:&tbnh=124&tbnw=101&prev=/images?q=stopwatch&gbv=2&ndsp=18&hl=nl&sa=N&start=36http://images.google.nl/imgres?imgurl=http://www.digizelgrafix.com/portfolio/images/lineart/stopwatch-bw.jpg&imgrefurl=http://www.digizelgrafix.com/portfolio/portfolio_lineart.html&usg=__EAiSrEAyFt92ozshRJX8sapHAXk=&h=400&w=325&sz=40&hl=nl&start=50&tbnid=vVzNTYyMALz9IM:&tbnh=124&tbnw=101&prev=/images?q=stopwatch&gbv=2&ndsp=18&hl=nl&sa=N&start=36http://images.google.nl/imgres?imgurl=http://www.digizelgrafix.com/portfolio/images/lineart/stopwatch-bw.jpg&imgrefurl=http://www.digizelgrafix.com/portfolio/portfolio_lineart.html&usg=__EAiSrEAyFt92ozshRJX8sapHAXk=&h=400&w=325&sz=40&hl=nl&start=50&tbnid=vVzNTYyMALz9IM:&tbnh=124&tbnw=101&prev=/images?q=stopwatch&gbv=2&ndsp=18&hl=nl&sa=N&start=368/10/2019 17 Solutions Available For Body Engineering.pdf
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Part Exchange - Initial Model
and New Model
Different outlines!
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Fully or semi-
automatic replace:Automatic recognition of new
flangesAutomatic definition of symmetry
E.g. recognition of redundant
rolling cylinder curves
Possibility to add new
functionalities (e.g. rolling
cylinders, profiles,..)Recognition of missing input
(flange) surfaces for part on
binder
Automatic or manual re-assigning
start points of floating profiles
Capabilities of Part Exchange
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The Total Time to Target is in this
Example Less then 2 Minutes
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Presented by Daimler AG at
German User Forum 2011
29
The milling result is very good and for a prototyping tool more thansufficient. The programming in TEBIS caused no problems whatsoever.
The Offset-Surfaces could be processed directly in TEBIS without any
problems.
Uwe Fisch er Mercedes -Benz Cars R&D
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Following Operations
Transfer of geometry via IGES
Final forming simulation
Springback compensation
Return of the compensated mesh into
CATPartOverbending of the die set with
DIGITIZED MORPHING
Offset
Generation of solidtooling
30
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PRECISION FORMING
Summary
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Precision Forming - This is the Task
32
and make sure
material properties are
right for performance
considerations
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Positioning
"Make sure that the panel comes off
successfully in the first shot"
E l I /O St
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Product design
Blank development
Thinningprediction
Forming LimitDiagram (FLD)
Examples: Inverse/One-Step
Simulation
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Applicable to :Progressive dies
Line dies
Transfer dies
Deep draw
Crash forming
Superplastic forming
Sheet & tube hydroforming
Tube bending
Tube and sheet hydroforming
Hot formingIroning
Coining
Stretch forming
Flex forming
Material:Titanium
AluminumStainless
Copper
HSS
Incremental Simulation: Overview
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Highthinning
Predicting common defects such as splits, wrinkles, spring back and
material thinning on computer
Providing customers with right first time
tooling to run production with a minimum
of manufacturing risk
Example Progressive Die
36
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-Process requiring Solid elements
-Strong Solids capabilities in PAM-STAMP2G (also used for coining)
Cracksprediction
Wrinklingprediction
Standard Stamping
Wh i Hi h St th St l
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Why is High Strength Steel more
Challenging
38
Mild Steel
590TS
980TS
AHSS (Ad d Hi h St th
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AHSS (Advanced High Strength
Steel) - Precision Forming
Bad
Formability
PamStamp 2G v2012 includes
more accurate and faster springback
for stamping of Ultra High Strength Steel
Mild Steel
590TS
980TS
Large
Springback
39
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Unbending
Opening
Twisting
Wall curvature
Spring-back/Compensation
40
Fi d th O ti l Bl k Si & T i Li
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Find the Optimal Blank Size & Trim Lines
with Automatic Optimization
41
Forming Restrike FlangingSpringback SpringbackBlanking
blank shape
Trimming Restrike FlangingSpringback SpringbackForming Trimming
trim lines
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Initial Blank shape optimization
LINE DIE OPTIMIZATION
42
After optimization
95% up to 1mm
Before optimization
18% up to 1mm
1stforming
2ndforming
restrike
Line Die Full Chain Simulation
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Line DieFull ChainSimulation,
Optimization, Quality Control
43
Forming Restrike Flanging HemmingSpringback Springback Springback Springback
www.carbodydesign.com
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Virtual Prototyping of all OPs
44
Forming Restrike FlangingSpringback Springback Springback
Source: Europam Toulouse 2006
Formability Analysis of Complex
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y y p
Automotive Panels and Full Process / Full
Cycle Simulation
45
Process validation and optimization, defects prediction before try-out
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Forming Restrike FlangingSpringback Springback Springback
Correction of springback
Multi-Ops Die compensation
Solve transfer: adapt
die from previous or
next OPs
Draw die
compensation
Compensate die
from multi-OP
springback
Automatic draw
and trim die
compensation
Y Tec manufactures an ultra high strength
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Using the Yoshida-Uemori model in PAM-STAMP 2G improves the accuracy of springback prediction
to a point where it becomes possible to determine effective qualitative countermeasures. By analyzing
the stress and strain accumulated during forming, we were able to determine and eliminate the cause
of poor dimensional accuracy. Thanks to PAM-STAMP 2G, we reduced the number of modifications on
the stamping tool even in cases where the parts formability was challenging, such as Ultra High
Strength Steel parts.
Y-Tec manufactures an ultra high strength
steel bumper with PAM-STAMP 2G's
springback correction
47
Hiroki Kondo, Deputy Manager, Advanced Press
Engineering Group/Dept. Y-Tec Corporation
Stress components which cause springback
Improvement of springback by reducing plastic strain
Courtesy of Y-Tec Corporation
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Gestamp successfully brings to market a
weight-optimized B-pillar stamped
from tailored blank using PAM-STAMP 2G
48
We achieved very good results thanks to
the accuracy of the simulation using PAM-
STAMP 2G. We were able to use thespringback prediction tool to evaluate the
die compensation, despite the complexity
of such a case with three different
thicknesses and two weld lines.
Eduardo Sulato and FbioLichtenthler
Engenharia da Matriceria
GestampAutomocinS.L.
Courtesy of Gestamp Automocion
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Hot Forming - Formability
Temperature on blank / tool
Martensite fraction during quenchingAfter 4 s After 8 s After 14 s
49
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Cooling Simulation of the Dies
50
3D tools with
cooling channels
Tool temperature at the end of quenching:
Courtesy of:
AP&T
Temperature at the End of Forming
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Temperature at the End of Forming
and Quenching
Temperature at the
end of forming
Temperature at the
end of quenchingCourtesy of:
AP&T
Casting Covers all Aspects of
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Casting Covers all Aspects of
Components
The whole is more than the sum of its partsAristotle
Microstructure Defects Properties States Dimensions
52
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NON-METALLIC COMPONENTS
Summary
53
Get it right with End-to-End Virtual
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End-to-End Virtual Prototyping Solution allows customers to deliver the
physical prototype right the first time.
Get it right with End to End Virtual
Prototyping Solutions
Build it right
Test it right
Deliver it right
Product Life Cycle
Forming
Infusion
Draping
Component simulation
System-level Simulation
54
Composites Materials and Processes
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Design flexibility / production rate
55
Reinforced
Thermoplastics
Mechanical
Properties/
Material
costs
Reinforced
Thermosets
Long fibersShort fibersunreinforced
2 mm
Injection molding Thermocompression Press Forming
RTM / Infusion - Vacuum Forming
Fiber length
Composites Materials and Processes
BMC SMC
6 mm 20 mm
Mats (GMT) Textile
Unidirectional
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Evaluate and optimize
Mold geometryProcess conditions
Vacuum strategy
Molding temperature
Through the prediction ofWrinkles
Thickness
Taking into accountThermal & strain rate effects
Thermoforming & Blowforming Simulation
Industrial Examples of Applications:
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Blow Forming (Gas Tank)
Thinning (%) DistributionSag under gravity (self-weight)
Blowforming
The Main Composites
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Pre-PregsLay pre-cut individualplies to build thelaminate
ORforming of complete pre-impregnatedlaminate
Cure at high temperature and pressure in anAutoclave
ORcuring in forming tools (OOA)
LCM (Liquid Composites Molding)Lay pre-cut dry fabrics to build the laminate
ORForming of dry fabrics
Injection/Infusion of dry fabrics
Curing in Injection/Infusion tools
The Main Composites
Manufacturing Options
Autoclave
Draped preform
Coutesy Renault
LCM Bracket Courtesy: CRCACS 2000+
58
P P F i Si l ti
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Pre-Preg Forming Simulation
Evaluate different forming strategies:Stamping, diaphragm (single or double) forming,
thermoforming
Clamping conditions, process parameters (tool velocity,
temperature, pressure)
Different Lay-up strategies
ESI solutions can help you:Reduce wrinkling
Eliminate bridging
Predict thickness of material after forming
Deliver optimum flat patternsDetermine final fiber orientation
Initial flat
pattern
Optimized flat
pattern
Poor part
quality
Improved
part
Simulation setup
Lower tool
Upper tool
4 plies
59
Aircraft Wingbox Simulation 8
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Courtesy: Br i t ish Aerospace
Actual Formed Part Simulated Part
Aircraft Wingbox Simulation 8
Plies (UD)
Thermoforming Process
Ply 1
As-built Fiber Orientation
60
A t l P
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Autoclave Process
Draping Curing Demolding
Thermo-Mechanical
Calculation
Fluid-Flow & Heat
Exchanges Calculation
Stress releaseLocal material properties
modification
Thermo-Mechanical Calculation
Internal stresses generation
61
Liquid Composites Molding
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PAM-RTM can evaluate and optimizeInjection strategy (RTM, VACUUM INFUSION,
VARTM)
Injection pressure and flow rate
Injection gates, vents and vacuum ports location
Molding temperature
Flow media
Through the prediction ofDry spots
Filling and curing times
Flow front velocity / Fiber washing
Pressure in the mold
Taking into accountFiber angle variation (permeability variation) of the
preform
Liquid Composites Molding
Simulation
R i Fl F t A l i
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Resin Flow Front Analysis
63
CF Floor Pan Infusion Courtesy TECABS: RENAULT
Mines Douai
Effects of Injection Conditions
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Micro-voids are directly proportional to the resin velocity
Critical impregnation velocity
For high performance composites, formation of micro-voids inside the
fiber tows should be minimizedMacro voids
Inter-tow
onto Mechanical Performance
(J. Brard)
64
Micro voidsintra-tow
Influence of Porosity on Stiffness
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y
& Strength
65
Draping and RTM Model
Lay-up
+ material
Lay-up definition
Draping and
Porosity effect
on mechanical
properties
Strength analysisDesign
Iteration
Simplified Process Setup for
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Engineers
66
Read multiple native
CAD modelsCATIA,
Pro/E, UGS NX, etc.
Create stamping tools
blank, rubber pad, etc.
Execute simple model
operations like translate,
etc.
Visual-Mesh
Create simulationprocess in wizard mode.
Encapsulate PS2Gto
generate the process.
Create Process block
library for future use
Visual-SDK, Visual-Process Exec
Display results
Extract reports
Visual-Viewer
What Makes the Difference:
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Assembly
OP 20 & 30 OP 40, 50, ..
Joining & Full Process Chain for Forming
Draw
Trim
Flange
Restrike
........
RollHemming
1
2
3
4
56
Welding
67
Casting ..
Those are the Engineering Disciplines
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Advancement in VehicleStructures & Safety
Materials Optimization for BodyEngineering
Body EngineeringDigitalOptimization
Manufacturing Engineering
g g p
Behind
68
Manufacturing Engineering
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Hemming
Cold and hot joining (welding)
Welding including history from sheet metalforming
g g g
Covers the Following
69
Roll Hemming
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Roll Hemming
70
Full forming process line
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Courtesy: UBSLIMATB - Universit de Bretagne-Sud
Rue de Saint Maud- BP 92116
56321 Lorient Cedexhttp://web.univ-ubs.fr/limatb
Forming Restrike Flanging HemmingSpringback Springback Springback Springback
Springback
between OP
g p
PamStamp 2G
71
Forming Restrike Flanging HemmingSpringback Springback Springback Springback
Flanging with ironing
simulation & impact
on springback
enhanced in v2012
with Hill 90, Barlat
Springback after
Hemming with glue
contact
enhanced in v2012
Table top and
Rollhemmingsimulation
Springback
between OP
Springback
between OP
Flanging HemmingSpringback Springback Springback Springback
PamStamp 2G simulation
With TTS elements
With ironing
Without ironing
http://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatb8/10/2019 17 Solutions Available For Body Engineering.pdf
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Distortion EngineeringWeld Planner - Joints
Advanced Modeling for Accurate
Si l ti W ld F ti Lif A l i
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PSA Objective: Decrease developmentdelay and cost, improve the quality
84 welding joints (total length 5 m)
Simulation: Weld - Fatigue Life Analysis
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Metallurgy Residual Stress Fatigue Criteria
GoalSheet Metal Forming and
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Joining to Manage Building Systems
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AssemblyForming Restrike Flanging HemmingSpringback
Spring
back
Spring
back
Spring
back
Based on one model and one platform
www.carbodydesign.com
Die Face
Design Based
on Geometry
Sheet Metal Forming
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with Spot Welding
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Spot-Weld AssemblyStamp Assembly sequence
Compensation
Some Details
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Import ComponentDeformed Shape from Stamp result
Thickness
Import Spot Weld Points
Automatic spot weld point assignment
Spot Weld Validation tool based on user
criteriaCheck Gap/Distance
Alignment /Angle
Component Penetration Area
Automatic Spot Weld Re-meshing tool
Export all information for Spot Welding
Assembly Simulation on Weld PlannerSpot Weld Sequence management
Penetration area for contact management
Some Details
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Spot Weld
geometrical validationtool in visual
Stamp- Spot Weld Assembly
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p p y
Simulation
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Processing in Weld PlannerSequence DefinitionAutomatic Gap Closing
Contact Management
Stamp- Spot Weld Assembly
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Final Stamp Spot Weld
Displacement Results
After Clamp Release
p p y
Simulation
Full Stamp Spot Weld deformed shape
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p p p
can easily be exported for hemming
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Laser Weld Assembly Chaining Solution
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Laser Weld Assembly Chaining Solution
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Those are the Engineering Disciplines
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Advancement in VehicleStructures & Safety
Materials Optimization for Body
Engineering
Body EngineeringDigitalOptimization
Manufacturing Engineering
Behind
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Modeling Tasks:
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Virtual Spot Weld Calibration
WELDING & HT
ANALYSES
3D SPOTWELD
MODEL
EQUIVALENT 1D
SPOTWELDMODEL
EI
Material properties
CCT diagrams
Process conditions
Local properties
EWK parameters?
Sample geometry
Test conditions
Force-deflection
Absorbed energy
Rupture model
& parameters
Force-deflection
Absorbed energy
M1 M2 M3
SIMULATION
CONTENT Mgt.
Data base
Development
M4
Tests results
3D results
1D Models
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Simulation of Rupture Modes
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Partial nugget pull-out and peeling of model
Ex. Mild Steel1 mm
100%
75%
50%
25%
0%
Martensite content:
T-tension Lap shear Cross tension
83
Stamping Effects to Improve
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Applicable in the pre-design phase
Consider real part properties in performance simulation
p g p
Virtual Performance Evaluations
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Virtual Performance Solution
b d Si l C M d l
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based on a Single Core Model
Crash & Safety
Stiffness & Misuse
NVH & I.Acoustics
Durability
Drivability
Comfort
Design iteration
Crash &
Safety
Stiffness &
Misuse cases
NVH & Internal
AcousticsDurability
Drivability
Comfort
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Current More Efficient
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PRODUCTS
Body Manufacturing
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What is Covered by VM - Materials
Optimization Component Manufacturing
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Advancement in VehicleStructures & Safety
Materials Optimization for Body
Engineering
Body EngineeringDigitalOptimization
Manufacturing Engineering
OptimizationComponent Manufacturing
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Task: Manufacturing of Components Under the
Aspect of Materials Optimization
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Aspect of Materials Optimization
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Closures / Outers
Inners
Chassis
not shown
here
Materials Optimization - Manufacturing of
Components Covers the Following
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Die Face Design & Early feasibility based on geometry
Die Maker based on CATIA and Visual Platform + feasibility
Cold precision forming
PS2G Getting the draw die right the first time
Zero tolerance buy off on the checking fixtureall followingoperations and quality checking at any stage
Hot Forming
PS2G
Casting
Quick / Procast
Components - Covers the Following
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Composites Processes Summary
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Unreinforced
Plastics
Continuous Fibers
Process:
Draping/Thermoforming
Process:
Resin Infusion
Process:
Thermoforming/Blowforming
Software:
PAM-FORM
Software:
PAM-FORM
Software:
PAM-RTM
Results: Results: Results:
Wrinkles
Thickness distribution (can be
used to update stress analysis
models)
Wrinkles
Thickness, strains & stresses
distributions
As-manufactured fiber
orientation (can be used to
update stress analysis models)
Filling time
Dry-spots
Micro & macro-voids (can be
used to update stress analysis
models)
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What is Covered by VMManufacturing
Engineering
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Advancement in VehicleStructures & Safety
Materials Optimization for Body
Engineering
Body EngineeringDigitalOptimization
Manufacturing Engineering
Engineering
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Manufacturing Engineering - Putting Components
Together - Covers the Following
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Roll Hemming
PS2G
Cold and Hot Joining
PS2G / Weld Planner (Feasibility) / Visual Weld(validation)
Welding including history from sheet metal forming andcasting (innovation)
Body manufacturing (project level)
Together - Covers the Following
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Goal
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Advancement in VehicleStructures & Safety
Materials Optimization for Body
Engineering
Body EngineeringDigitalOptimization
Manufacturing Engineering
VMS