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Altair's Student Guides - Instructor's Manual - CAE for Simulation of Sheet Metal Forming

Altair's Student Guides - Instructor's Manual - CAE for Simulation of Sheet Metal Forming

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Published by KFourMetrics
Designed for use by Engineering Students, this book provides 4 industry-derived projects for use with Altair's HyperForm and Radioss. Together with the accompanying Student Guide, they provide a quick, complete and correct introduction to using this software to simulate the forming of sheet metal.

For more learning resources on HyperWorks and CAE, for both students and teachers, see http://www.altair-india.com/edu/students
Designed for use by Engineering Students, this book provides 4 industry-derived projects for use with Altair's HyperForm and Radioss. Together with the accompanying Student Guide, they provide a quick, complete and correct introduction to using this software to simulate the forming of sheet metal.

For more learning resources on HyperWorks and CAE, for both students and teachers, see http://www.altair-india.com/edu/students

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Published by: KFourMetrics on Nov 21, 2008
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05/09/2014

 
Student Project Summaries CAE for Simulation of Metal Forming1ContentsIntroduction.............................................................................................2
 
Installation Instructions:.......................................................................2
 
Simulation of Springback in Aluminum.......................................................3
 
Description of the Problem....................................................................3
 
Data Organization.................................................................................4
 
Building the Tool...................................................................................4
 
Process Parameters...............................................................................5
 
The Nonlinear Solution..........................................................................6
 
Results and Design Modifications...........................................................6
 
Further Work........................................................................................7
 
Summary.............................................................................................8
 
Blank Size Optimization for an A-Pillar.......................................................9
 
Description of the Problem....................................................................9
 
Data Organization...............................................................................10
 
Building the Tool.................................................................................10
 
Process Parameters.............................................................................11
 
The Nonlinear Solution........................................................................12
 
Results and Design Modifications.........................................................12
 
Further Work......................................................................................13
 
Summary...........................................................................................13
 
Optimization of Blankholding Force for a Seat Riser..................................15
 
Description of the Problem..................................................................15
 
Data Organization...............................................................................16
 
Building the Tool.................................................................................16
 
Process Parameters.............................................................................17
 
The Nonlinear Solution........................................................................18
 
Results and Design Modifications.........................................................18
 
Further Work......................................................................................19
 
Summary...........................................................................................19
 
Multi-stage Forming of a Suspension Cover..............................................21
 
Description of the Problem..................................................................21
 
Data Organization...............................................................................22
 
Building the Tool.................................................................................22
 
Process Parameters.............................................................................23
 
The Nonlinear Solution........................................................................24
 
Results and Design Modifications.........................................................24
 
Further Work......................................................................................25
 
Summary...........................................................................................26
 
 
Student Project Summaries CAE for Simulation of Metal Forming2
Introduction
This material is best used after reading the book 
Managing The CAE Process 
. Access to HyperWorks software is not essential for you, the instructor. Of course, if you choose to solve the problems yourself before working withyour students, you will need HyperForm, Radioss, HyperView andHyperGraph.This book describes 4 assignment problems that highlight differentapplications of HyperWorks. Each problem is independent, and is completein itself. Students may choose to do more than one, depending on theirinterest.To make best use of this material you will need a computer with a sound-card and speakers. Your computer should have a media-player program(such as Windows Media Player) and an Internet Browser that supportsJavaScript. The material can be copied to a server and accessed by clients. You can customize the HTML files to suit yourrequirements. After opening the file, double-click on any text to edit it. Use the
save changes 
 link on the left of your Browser window whenyou are finished.
Installation Instructions: 
1. Copy the folders to your computer or to your server. If you areworking on a server, it is a good idea to set the folders to “readonly” to prevent inadvertent modifications.2. The videos are best played in full-screen at a resolution of 1024 x768. You may need to install the
CamStudio Codec 
to view video onyour computer. To do this, right-click on the file
camcodec.inf 
andchoose
Install 
from the popup menu. You may need administratorprivileges to do this.3. Ensure that JavaScript is enabled on your browser.4. Each folder contains one HTML file. Double-click on it to open theinstructions.5. Data files are provided as relevant – IGES files, HM files, etc.6. In case you need support, contact your distributor or emailedu.support@altair.india.com
 
Student Project Summaries CAE for Simulation of Metal Forming3
Simulation of Springback in Aluminum
 Areas covered: 
Data import and geometry cleanup 
Layout and organization of components of the  press-tool 
Specification of process parameters 
Controlling the incremental solver for explicit forming analysis and implicit springback analysis Software used: 
HyperForm 
Radioss 
HyperView 
HyperGraph 
Description of the Problem 
 Aerospace components often use aluminum for theweight advantage it provides over steel.Unfortunately, aluminum has two disadvantagesfrom a forming perspective. First, its behavior ismore sensitive to the strain-rate than ordinarysteels. Second, it is more prone to springback -recovery of elastic strains after forming.The component that has been supplied to a diedesigner is geometrically simple, but the pressshop has no experience in working with Aluminum.The range of forces to be used, for both the blank holder and the ram, are to be verified. Further, thedie designer has to confirm whether thecomponent will pass dimensional checks afterforming, or whether springback must becompensated for - either by forming thecomponent a little too much or by using asubsequent operation.So the analyst must cover two distinct steps.The first is to check for the effect of springback.The task is complicated by the fact that the pressshop has not supplied material data for Aluminum. Aerospace manufacturers tend to be very specific

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