Abstract
Accurate modelling of sheet metal forming can contribute significantly to reduction of lead time and development costs in manufacturing industries. The current way to improve the finite element model accuracy is to combine advanced constitutive material models and advanced tribological models. For model validation purposes the geometry of the forming tools needs to be updated and the most relevant parameters of the forming press needs to be incorporated. The addition of a simple and easier to control model test can offer additional information on difficult to characterize parameters of the industrial process. The industrial validation case presented in this paper demonstrates that the Tata Steel constitutive material model has similar prediction capability as the state of the art material model used at Volvo Cars for regular process development for automotive parts production. In both industrial and model tests the tribological system appears to affect significantly the overall model accuracy. The model tests suggests that further work is needed in order to improve the tribological model description at high contact pressure and high strain levels.
Highlights
Accurate modelling of sheet metal forming can contribute significantly to reduction of lead time and development costs in manufacturing industries
This model predicts the dependence of the friction coefficient on contact pressure, sliding velocity, plastic strain and temperature, specific for a tribological system defined by lubricant type and quantity, material surface
The industrial validation case demonstrates that the Tata Steel material model has similar prediction capability as the state of the art material model used at Volvo Cars for regular process development for automotive parts production
Summary
Accurate modelling of sheet metal forming can contribute significantly to reduction of lead time and development costs in manufacturing industries. The current state of the art tribological system model is offered by TriboForm [3] and [4] This model predicts the dependence of the friction coefficient on contact pressure, sliding velocity, plastic strain and temperature, specific for a tribological system defined by lubricant type and quantity, material surface. The stamping model accuracy can be estimated by comparing the model prediction with draw in and strain measurements on the formed parts Such an exercise requires an update in the model of the geometry of the stamping tools due to the fact that the current geometry can be significantly altered during setting up series production processes. Such a test offers better experimental control and possibility to isolate particular effects experimentally and makes easier to distinguish between various contributions to the overall model accuracy
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Free) 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
