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

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

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Published by KFourMetrics
Designed for use by Engineering Students, this book provides background reading for use with Altair's HyperForm and Radioss. Together with the accompanying Projects and their Instructor's Manual, it provides 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 background reading for use with Altair's HyperForm and Radioss. Together with the accompanying Projects and their Instructor's Manual, it provides 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

 
CAE for Simulation of Metal Forming Contents
1
Contents
Introduction......................................................................................................2
 
 About This Series...........................................................................................2
 
 About This Book.............................................................................................2
 
Supporting Material........................................................................................3
 
Product Design vs. Tool Design..........................................................................4
 
Design Principles............................................................................................4
 
Conflicting Demands.......................................................................................5
 
Tool Design - Analysis, Design and Optimization..............................................7
 
Summary.......................................................................................................8
 
Metal Forming An Overview.............................................................................9
 
Metals – Cradle To Grave................................................................................9
 
Sheet Metal..................................................................................................10
 
Drawing The Fuller Picture............................................................................12
 
Critical Data - Material Properties..................................................................19
 
Its (Almost) All About Steel...........................................................................22
 
Numerical Analysis – An Introduction................................................................24
 
Numerical Models.........................................................................................24
 
Important Terms..........................................................................................28
 
Summing Up................................................................................................32
 
Finite Element Methods and Forming................................................................33
 
 A Retrospective............................................................................................33
 
The Tool Designer and The Analyst...............................................................35
 
The Product Designer and The Analyst..........................................................37
 
Incremental Analysis - Numerical Aspects......................................................38
 
Summary.....................................................................................................42
 
Putting It All Together: HyperForm...................................................................43
 
Process-Centric Modeling..............................................................................43
 
Forming Simulation – What and How.............................................................44
 
Summary of Steps Involved..........................................................................49
 
 Advanced Topics.............................................................................................51
 
Commercial Terms.......................................................................................51
 
Data Files – What Goes Where......................................................................52
 
Glossary And References..................................................................................54
 
References...................................................................................................59
 
Other Resources...........................................................................................59
 
Sample Material Properties............................................................................59
 
 
Introduction CAE for Simulation of Metal Forming
2
Introduction
About This Series 
To make the most of this series you should be an engineering student, inyour third or final year of Mechanical Engineering. You should have accessto licenses of HyperWorks, to the Altair website, and to an instructor whocan guide you through your chosen projects or assignments.Each book in this series is completely self-contained. References to othervolumes are only for your interest and further reading. You need not befamiliar with the Finite Element Method, with 3D Modeling or with FiniteElement Modeling. Depending on the volumes you choose to read, however,you do need to be familiar with one or more of the relevant engineeringsubjects:
Design of Machine Elements 
,
Strength of Materials 
,
Kinematics of Machinery 
,
Dynamics of Machinery 
,
Probability and Statistics 
,
Manufacturing Technology 
and
Introduction to Programming 
. A course on
Operations Research 
or
Linear Programming 
is useful but not essential.
About This Book 
Of all the books in this series, this is by far the easiest for a mechanicalengineer to understand. The subject is far less abstract than those coveredin the other books, and the immediate relevance of the methods discussed isremarkable. Like the other books in this series, it is self-contained. Access toa press-shop, of course, will not only be extremely useful, it’s almostindispensable.While a knowledge of FEA won’t hurt, it is not essential. As we will see, thetechniques used are at the very cutting edge of numerical analysis, butthese are so closely aligned with physically meaningful manufacturingprocesses that an understanding of manufacturing technology is more thanenough to appreciate, to learn, and to bring this power to bear.The various references cited in the book will probably be most useful afteryou have worked through your project and are looking for ways to increasethe depth of the simulation techniques you have learned.
 
CAE for Simulation of Metal Forming Introduction
3
Supporting Material 
 Your instructor will have the Instructor’s Manual that accompanies thesevolumes – it should certainly be made use of. Further reading andreferences are indicated both in this book and in the Instructor’s Manual.If you find the material interesting, you should also look up the HyperWorksOn-line Help System. The Altair website,
www.altair.com 
, is also likely to beof interest to you, both for an insight into the evolving technology and tohelp you present your project better.
 
You have your way. I have my way. As for the right way, the correct way, and the only way, it does not exist.
Friedrich Nietzsche 

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