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Integrated Process Simulation and Die-Design in Sheet Metal Forming
Integrated Process Simulation and Die-Design in Sheet Metal Forming
DOI 10.1007/s12289-008-0022 -3
# Springer/ESAFORM 2008
ABSTRACT: During the recent 10-15 years, Computer Aided Process Planning and Die Design evolved as
one of the most important engineering tools in sheet metal forming, particularly in the automotive industry.
This emerging role is strongly emphasized by the rapid development of Finite Element Modelling, as well. In
this paper, an integrated process simulation and die design system developed at the University of Miskolc,
Department of Mechanical Engineering will be introduced. The proposed integrated solution has great
practical importance to improve the global competitiveness of sheet metal forming in the very important
segment of industry. The concept to be described in this paper may have specific value both for process
planning and die design engineers.
Key words: Process planning, Die-design, Integrated FEM simulations
1 INTRODUCTION
The global competition requires that manufacturing
industry besides the skill and the experience
accumulated in the shop practice should
increasingly utilise proven techniques of Computer
Aided Engineering including numerical simulation
and modelling for rapid and cost effective process
design and tool manufacturing. The application of
various methods of Computer Aided Engineering
has become one of the most important topics in
manufacturing industries and particularly in the
automotive industry [1].
The application of various CAE techniques
practically should cover the full product development cycle from the conceptual product design
through the process planning and die design up to
the manufacturing phase of the production. CAE
techniques are widely used in sheet metal forming,
for example to predict the formability, to determine
the type and sequences of manufacturing processes
and their parameters, to design forming tools, etc.
[2]. The importance of the application of CAE tools
becoming more and more important as the
manufactured parts are becoming ever increasingly
186
x
x
x
187
Product
design
Product
redesign
Failed
Incremental Good
Forming
Simulation
Process
or die
redesign
Failed
Die
manufacturing
Prototyping Good
Production
& Tool
try-out
Die
correction
Failed
188
4.
5.
4 CONCLUSIONS
The application of various methods of computer
aided engineering has a vital and central role in the
recent developments in sheet metal forming
concerning the whole product development cycle.
The application of various methods and techniques
of CAE activities resulted in significant
developments: the formerly trial-and-error based
workshop practice has been continuously
transformed into a science-based and technology
driven engineering solution.
In this paper, an integrated approach for the
application of knowledge based systems and finite
element simulation is introduced. Applying this
knowledge and simulation based concept for the
whole product development cycle from the
conceptual design through the process planning and
die design as an integrated CAE tool provides
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