Papers by Keyword: AutoForm

Abstract: Predicting the final shape of automotive structural components after springback is a challenge to the inclusion of high strength aluminum alloys into the vehicle body-in-white. Complex deformation paths and reverse loading of sheet material during forming operations can induce significant Bauschinger effects and kinematic hardening behaviour. Capturing the through-thickness stress gradient is critical when predicting springback, which is governed by tooling dynamics, frictional forces, and material plasticity. In this study, the anisotropic behaviour of a AA6xxx-T4 aluminum alloy was characterized to calibrate a BBC2005 yield function, kinematic hardening effects were characterized through a novel uniaxial compression-tension technique, and a technology demonstrator U-shaped rail component was formed and scanned to assess the final shape after springback. Multiple model variations were analyzed in AutoForm R12, modifying simulation control parameters, binder loading condition (uniform vs. column), friction model (Coulomb vs. TriboForm), and hardening model (isotropic vs. kinematic). The use of column binder loading paired with TriboForm friction model provided the most significant improvement for thinning and springback prediction accuracy with kinematic hardening being a second order effect compared to accounting for friction and binder force.

Abstract: In the aerospace industry, hot forming processes, using materials like Ti-6Al-4V titanium, are known for their complexity and cost. Senior Aerospace Thermal Engineering (SATE) has traditionally relied on a trial-and-error approach for new product introductions (NPIs), which, while effective, has led to significant time and resource expenditures. This paper examines the transition of SATE's NPI processes to a more efficient digital approach using AutoForm Forming simulation software. By doing so, SATE has been able to accurately predict forming outcomes, optimize tooling designs, and significantly reduce both the number of physical tryouts and the overall project costs. Two case studies are presented to demonstrate the practical applications of this digitalization, highlighting how important engineering decisions were taken. The paper concludes with an assessment of the impact on SATE's operations, noting improvements in development time, feasibility assessments, and overall production efficiency.

Abstract: Residual stress generated in the body parts during stamping process influences on its structural strength and stiffness partly. In this paper, the formality, stiffness and strength of hood-outer panel had been analysis based on Autoform and Altair-hypermesh, and the diagrams of major strain and plastic strain are shown. Compared the results by Geomagic Qualify; there are the same areas of stress concentration from the results. According to this, the body parts can be optimized to get excellent preference of stiffness and strength.

Abstract: Commonly investigated problem on composite fabrication and forming for weight reduction in transportation and aerospace area is not completely cleared. The main difficulties on composites forming without building any defects caused new ways on process characterization due to the key parameters. In the paper two main problems were investigated, i.e. material fracture and material thinning during deep drawing. Through mechanical tests and numerical simulation the authors tried to couple the fracture with the technological boundary conditions of the deep drawing process and form a housing test part from a three-layer material.

Abstract: Describe an advanced design and manufacturing technology Concurrent Engineering (CE) and give the automobile covering parts mould development flow basing on concurrent engineering. It tries to consider initially all factors of the mould development life cycle. Take an automobile covering part for example. Basing on the finite element analysis software AUTOFORM, do die design and forming simulation. According to the result of simulation, designer can predict the defect of forming and timely modify the forming process. So in stage of process design taking into account the blank forming, this kind of concurrent design of the mould surface can be directly used to mould design, also won't return after the mold design to modify the die-face design process. So on account of concurrent engineering, it can reduce the changes of automobile covering parts mould design and the number of repeated test, improve quality, reduce cost, and shorten the cycle of mould development.

Abstract: ST14 material around the back door window frames of the front bracket parts for the carrier, and to AutoForm stamping process finite element analysis software as a platform for ST14 experience of the material structure process simulation of material forming process, the analysis of the parts stamping process defects through repeated amendments of Part Process structure, to achieve the purpose of stamping process defects.

Abstract: The design of a suitable forming process for a stamped part is a complex issue. Many boundary conditions must be fulfilled and many considerations must be made to come to a successful solution. Elimination of wrinkles and splits very often need contrary counter-measures and, more often than not, it is both an iterative and subjective process. AutoForm Engineering has thus developed a methodology whereby stamping issues are automatically detected, based on all important failure and quality criteria, and which enables automatic tracking of engineering progress. This paper introduces a systematic approach which reduces the number of loops in the effective design of a forming process and allows the streamlined evaluation of multiple simulations in order to determine the most influential parameters to generate the best solution. The automatic detection of stamping issues and subsequent systematic process improvement will be illustrated using both an academic part and a real automotive component.

Abstract: Industrial thin slab casting and direct rolling processing started in 1989 with the world’s first CSP® plant at Crawfordsville (USA). Since this time CSP® and competing thin slab casting and direct rolling concepts have been developed to a standard process for hot strip production [1]. Typical features of the CSP® process are the homogeneous structural and mechanical properties all along the strip. Direct hot rolling of thin slabs may be followed by a well defined cooling pattern to produce hot strip from high strength multiphase steel, like dualphase (DP) grades, on the runout table. These steel grades are characterized by a favorable combination of strength and ductility based on hard martensitic particles embedded in a ductile ferritic matrix. This paper highlights the mechanical properties of hot rolled DP steel from CSP® production. To this purpose, multiple tests and modeling have been applied to determine e.g. r-values, forming limit curves and yield locus. In addition, forming simulation as well as laboratory and industrial deep drawing tests have been performed.

Abstract: The purpose of the present research is to investigate and improve the quality of car brake booster deformed under drawing processes by using Finite Element (FE) program known as AutoForm. The materials are made from SPC270F with thickness 1.4 mm. and the initial diameter of 280 mm. The brake booster requires totally 9 production processes, including the sheet blanking, in the manufacture. Failure has found in the 4^th draw in which cracking occurs at the bottom of cylinder. The material property assumed to be anisotropic, behaved according to Ludwik’s equation, and deformed rigid-plastic, which followed Hill’s yielding surface. The deformation for Forming Limit Diagram (FLD) was predicted by Keeler equation. Punch and die were assumed to be rigid during simulation. In this work, the process improvement focus mainly on the smallest change in die design which no lubricant required during the drawing processes. From the predicted results, the recommended punch diameter for the 1st draw should be extended to 111.4 mm while the new design for die’s diameter in the 1st draw is as large as 103 mm. However, punch’s height and its radius need to be varied in order to prevent the wrinkle as well. Since there is a little change in the new design while no more lubrication is required during the draw process, its can be improved in quality of finish product, cost reduction in lubricant consuming as well as the machining time to make a new punch.

Abstract: The features and functions of Autoform software for sheet metal forming simulation were introduced. Taking the auto panel as an example, based on UG and Autoform, the process of CAE simulation analysis on the drawing process was stated in this paper and the simulation results were analyzed. The results of analyses indicated that the crack tendency was in the two salient of auto panel flange in the drawing process. By optimizing and adjusting the parameters of mold, the problem of crack tendency was solved. The optimal stamping process was finally determined based on the results of the simulation. Compared with the traditional stamping technology and die designing, the quality of die designing was improved by adopting CAE technique.