Simulation For Forming

CPF Simulation and Optimization of Metal Forming Processes
Taylan Altan, Professor and Director (altan.1@osu.edu) Center for Precision Forming www.cpforming.org Engineering Research Center for Net Shape Manufacturing (ERC/NSM) www.ercnsm.org The Ohio State University, Columbus, Ohio USA Prepared for
Brazilian Metallurgy and Materials Association-ABM 63rd Annual Conference-July 28-31, 2008- Santos/SP-Brazil
Center for Precision Forming (CPF)
1
Presentation Outline
1. Introduction 2. Determination of sheet material properties
Flow stress Bulge test as an indicator of incoming sheet quality
CPF
3. Tests to evaluate lubricants for stamping

The deep drawing test The ironing test The modified limiting dome height (MLDH) test
4. Case studies in process simulation

Multi-point Cushion Systems (MPC) Warm forming of Al alloys, Mg alloys and High Strength Steels (HSS)
5. Summary
Introduction
CPF
Stamping process as a system (e.g., the deep drawing process)
1. Workpiece material / Blank 2. Tooling 3. Interface 4. Deformation zone
5. Equipment 6. Part 7. Environment
Introduction
CPF
FE simulation is widely used in sheet metal forming as a virtual press to:

Predict material flow, stress, strain, temperature, potential failure modes Troubleshoot a new problem Validate tool/die designs by engineers
Successful application of FE simulation depends on:

Reliable input material properties (e.g., flow stress data, anisotropy coefficients) A good understanding of the problem (e.g., boundary conditions such as workpiece/tool temperatures, interface friction)
Determination of sheet material properties CPF

In common practice, the uniaxial tensile test is used to determine the properties/flow stress and formability of sheet metal. Tensile test does not emulate biaxial deformation conditions observed in stamping. Due to early necking in tensile test, stress/strain data (flow stress) is available for small strains.
Necking begins
Engineering Stress-Strain Curve
True Stress-Strain Curve = Flow stress
In AHSS, the strain hardening exponent [n-value] and Youngs modulus [E] change with deformation (strain).
5

Schematic of viscous pressure bulge test (VPB) tooling setup at CPF
Potentiometer
Sheet
Viscous medium Pressure transducer Stationary Punch

6
Before forming
After forming

Schematic of viscous pressure bulge test (VPB) tooling setup at CPF
Clamping force
Die diameter = 4 inches (~ 100 mm) Die corner radius = 0.25 inch (~ 6 mm)
Bulge/ Dome height (h) Pressurized medium
Initial Stage
Testing stage
Pressure (P)
Methodology to estimate material properties from VPB test, developed at CPF

Measurement
Pressure (P) FEM based inverse technique
Material properties
Flow stress Anisotropy
Dome height (h)


Bulge test (VPB) samples
Before bursting After bursting
10 inches (~ 250 mm)
4 inches (~ 100 mm)

Flow stress results for sample materials from the bulge test
CPF has conducted a number of industrial case studies for:
Automotive - OEM, Automotive - Tier 1 suppliers Aerospace companies, NASA, Steel producers, etc.,
DP500 (Tensile test)
DP500 (Bulge test)
BH210 (Bulge test) BH 210 (Tensile test )

Bulge test as an indicator of incoming sheet quality
Graph shows dome height comparison for SS 304 sheet material from eight different batches/coils [5 samples per batch].
Highest formability G , Most consistent F
Lower formability and inconsistent H

10
Applications of the bulge test
CPF
The bulge test is conducted in biaxial state of stress, thus emulating the deformation conditions in common stamping operations.
True stress true strain (flow stress) data is obtained over larger strains (nearly twice that of uniaxial tensile test). Accurate flow stress data is a necessary input to process simulation/virtual die tryouts using FEM.
Dome or bulge height at bursting is a good measure of formability of the sheet material. In comparing different materials of the same sheet thickness, a larger/higher dome height at bursting, indicates better formability. Dome height at bursting can be easily used to identify variation in sheet material property which is commonly attributed to:
a. different incoming coils, and

b. different material suppliers.
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Stamping lubricants in the automotive industry

Process with oil-based (wet) lubricant
Pre-Oiling (optional) Additional Oiling (optional)
CPF
Degreasing (optional)
Decoiling and cutting
Stacking Blanks (dry or pre-oiled)
Deep Drawing + subsequent blanking operations
[Courtesy: M. Pfestorf, 2005, BMW ]

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Stamping lubricants in the automotive industry

Process with dry-film lubricant
CPF
Decoiling / Recoiling with Lube coating by immersion or spraying
Decoiling and cutting
Stacking Blanks
Deep Drawing + subsequent blanking operations
Hot bath
[Courtesy: M. Pfestorf, 2005, BMW ]

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Test to evaluate lubricants for stamping

The deep drawing test
CPF
The deep drawing test has been used successfully for evaluating lubricants supplied by various manufacturers. CPF is further developing this test for quantitative ranking of lubricants.
12 inch
Initial blank
6 inch
Deep drawn cup
Schematic of deep drawing tooling at CPF

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Test to evaluate lubricants for stamping CPF

Schematic of the deep drawing test
As blank holder pressure (Pb) increases, frictional stress () increases based on Coulombs law.
Coulombs law
P b where = the frictional shear stress the coefficient of friction

Pb = the blank holder pressure
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Performance evaluation criteria:
The maximum drawing load attained Maximum applicable Blank Holder Force (BHF) without failure of the cup
Measurement of draw-in length, Ld, or perimeter of flange in a drawn cup

Evaluation of lubricant build-up on the die for dry film lubricant
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Lubricants are ranked based on the highest constant BHF that can be applied in deep drawing before the cup fails.
BHF = 50 tons Test speed = 65 mm/sec
Load-stroke curves of formed vs. fractured cups

17

Comparison of draw-in length for various lubricants
18
Case studies in process simulation

Multi-point Cushion systems (MPC)
Current trends to control material flow in stamping
CPF
Draw beads mainly control material flow, Blank Holder Force (BHF) avoids lift of blank holder/binder
Constant BHF applied throughout press stroke, at all locations of the blank holder/binder using:
Nitrogen cylinders in the dies Presses with hydraulic and pneumatic cushions Requirements for robust quality stamping/sheet hydroforming
Variation of BHF with stroke Springback control

Variation of BHF at different locations within blank holder/binder Enhance drawability Variation stroke to stroke, coil to coil Allow variability in sheet material properties, thickness, lubrication and others.
19

Developments in BHF application technology
CPF
Each cushion pin is individually controlled (hydraulic/ nitrogen gas /servo control).
Offers a high degree of flexibility

Die
Blank holder / Binder
(Source: Mller Weingarten)
Individual cylinders for each cushion pin
Location of cushion pins/ cylinders in the die
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Possible variations in BHF application
CPF
Constant in location, Constant with stroke: Current practice

Each cushion pin applies same force that is kept constant in stroke
Single point cushion system, nitrogen cylinders or hydraulic cylinders Constant in location, variable with stroke
Each cushion pin applies same force that is varied in stroke (hydraulic)
Single point hydraulic cushion system Variable in location, constant with stroke Each cushion pin applies different force that is kept constant in stroke Multipoint control hydraulic cushion system, nitrogen cylinders Variable in location, variable with stroke Each cushion pin applies different force that is varied in stroke(hydraulic) Multipoint control hydraulic cushion system
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Nitrogen gas spring systems
CPF
Nitrogen pressure control panel
Top view of a two pressure-zone configuration
Individual cylinders for each cushion pin
Top view of a three pressure-zone configuration (Source: HYSON, Nitro-dyne)
22

Hydraulic systems
CPF
IFU flexible Blank holder / Binder hydraulic control unit (Source: IFU, Stuttgart)
Erie binder unit (hydraulic system) with liftgate tooling inside press (Source: USCAR)
23

Application of MPC die cushion technology in stamping
CPF
Sample cushion pin configuration (hydraulic MPC unit) for drawing stainless steel double sink.
(Source: Dieffenbacher, Germany) MPC is routinely used in deep drawing of stainless steel sinks
24

Previous work at CPF in Blank Holder/Binder Force (BHF) determination
CPF
CPF in cooperation with USCAR consortium developed software to program MPC die cushion system in stamping. Methodology for BHF determination (Numerical optimization techniques coupled with FEA)
Inputs required
Quality control parameters (wrinkling, thinning) No. of cushion cylinders (n) Tool geometry (CAD) Material properties Process conditions
Software developed at CPF for BHF determination FEA Software (PAM-STAMP, LS-DYNA)
BHF at each cushion pin as function of punch stroke
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Die
CPF
FE model
Estimation of Blank Holder Force (BHF) varying in each cushion pin & constant in stroke, using FE simulation coupled with numerical optimization, developed at CPF. Sheet
Geometry : Lift gate inner Material : Aluminum alloy, AA6111-T4 Initial sheet thickness : 1 mm
Beads
Inner Binder Cushion Pin Punch
Segmented blank holder [Source: USCAR / CPF - OSU]
Outer Binder
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BHF predicted by FE simulation in individual cushion pins for forming Aluminum alloy (A6111-T4, sheet thickness = 1 mm)
120
Blank holder force (kN)
CPF
11
10
100 80 60 40 20 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Pin numbers
15
9 8 13 7
6
14 Pin 1 2 12 3 5 4
Pin locations and numbering

27

Experimental validation of BHF prediction by FE simulation Bake Hardened steel (BH210, t = 0.8 mm) No wrinkles, no tears
CPF
Aluminum alloy (A6111 T4, t = 1 mm) Minor wrinkles, no tears
Dual Phase steel (DP600, t = 0.8 mm) No wrinkles, no tears
Using a hydraulic MPC system installed in mechanical press, the auto-panel was formed successfully - with three different materials/sheet thicknesses in the same die by only modifying BHF in individual cushion pins.
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Ongoing work Sheet Hydroforming with Die (SHF-D) process In cooperation with IUL, Dortmund Stamping
CPF
In cooperation with IWU Fraunhofer Institute, Chemnitz Punch
Die
Segmented elastic blank holder with multipoint cushion system
Blank Blank holder
Die
Cushion pins
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Potential future work in BHF estimation for MPC systems
CPF
Even with predicted optimum BHF, there can be inconsistency in metal flow in production. This inconsistency can be attributed to the variations in: sheet material property (variations in incoming coil/different supplier) & process conditions such as lubricant behavior (smearing), tool temperatures, etc. A methodology is needed to modify/adjust the BHF (by modifying nitrogen gas/hydraulic pressure) in individual cushion pins during production, such that the obtained draw-in (flange outline) matches the draw-in (flange outline) for a good part.
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Potential future work in BHF estimation for MPC systems
CPF
Schematic shows mismatched draw-in (flange outlines) seen in top view for a sample
part.
An imaging system could be used as feedback to obtain and compare flange outlines.
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Warm forming of Al alloys, Mg alloys and High Strength Steels (HSS)
Challenges in process simulation
CPF
Lack of reliable input data for FE simulation
Flow stress of sheet material at relevant strain, strain rate and temperature Thermal properties of sheet material at different temperature Interface friction coefficient at higher temperature between dissimilar metals in contact Interface heat transfer coefficient between dissimilar metals in contact
Lack of knowledge on the yield surface to describe yielding behavior of metals at elevated temperature in FE codes. Lack of knowledge on the strain softening behavior exhibited by metals at elevated temperature to consider in FE simulation.
32

Warm forming of Al alloys, Mg alloys and stainless steels
Elevated temperature formability study: Schematic of warm forming tooling at AIDA America, Dayton
Die Ring Die Holder Punch
CPF
Blank Holder Cartridge Heaters Lower Tool
Cartridge Heaters Upper Tool
Heated tool Stage 1 Stage 2 Stage 3
Cooled punch
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Elevated temperature formability study: Servo Press at AIDA America, Dayton
Power Source Capacitor Balancer tank Main gear
CPF
Servomotor Drive Shaft
34

Results of elevated temperature formability study
3
CPF
Limiting Drawing Ratio (LDR)
2.9 2.8 2.7 2.6 2.5 2.4 250 275 300 Die and Blank holder temperature (deg C)
Material Al5754-O, t = 1.3 mm

Forming velocity = 5mm/sec Influence of temperature on the deep drawability of round cups ( 40 mm) was investigated. Similar studies were conducted for higher forming velocities of 15 mm/sec and 50 mm/sec.
[In cooperation with AIDA America, Dayton]

35
Process Modeling Applications -Progressive Die Design-
CPF
A process sequence was designed for the part shown. The existing design was improved through FE simulation to reduce the potential for failure in the formed part (excessive thinning and wrinkling).
36
Process Modeling Applications -Incremental Forming-
CPF
Orbital Forming of Wheel Bearing Assembly: . Determine the influence of various process parameters such as axial feed, tool axis angle, etc., on the residual stress in the bearing inner race of the assembly, deformed geometry of the spindle, and the axial load that the assembly can withstand
Tool
Inner race
Spindle
Initial stage
Final stage
37
Process Modeling Applications -Microforming of Medical Devices-
CPF
Microforming of a Surgical Blade: Using FEA with die stress analysis, the flash thickness was reduced such that grinding of flash was replaced by electro-chemical machining (ECM). The designed tool geometry was successfully used in production to coin this part.
Initial blank
Formed part
(Blank thickness = 0.1 mm; Final blade thickness = 0.01 mm)
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Process Modeling Applications -Material Yield Improvement in Hot Forging-
CPF
Hot Forging of Suspension Components: A study was conducted for a tier one aluminum forging supplier to optimize the preform and die (blocker and finisher) designs, forging temperatures as well as flash dimensions.
39
CPF
Process Modeling Applications -Material Yield Improvement in Hot ForgingMaterial yield was increased by 15% through preform optimization, with an additional 3-4 % improvement through blocker die design.
Original Finisher Forging
Final Forging with Reduced Flash
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Summary
CPF
Process simulation using FEA is state of the art for die/process design. Determination of reliable input parameters [material properties /interface friction conditions] is a key element in successful application of process simulation. For practical application, stamping lubricants should be evaluated in the laboratory under near-production conditions (speed, temperature, interface pressure). Reliable friction coefficient values needed for process simulation can be obtained from these laboratory tests. Multi-point control (MPC) die-cushion systems offer high flexibility in process control, resulting in considerable improvement in formability. MPC systems demonstrate good potential in forming light weight/high strength materials. Reliable flow stress data at elevated temperature is required as an input for accurate FE simulation of the warm forming process. Considerable research on warm forming process and its application to production is in progress. Intelligent use of process modeling saves time & costs and increases precision of formed parts.
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Questions / Comments
CPF
Contact information: Taylan Altan, Professor and Director Center for Precision Forming - CPF (formerly, Engineering Research Center for Net Shape Manufacturing ERC/NSM) www.cpforming.org / www.ercnsm.org The Ohio State University, Columbus, Ohio USA Email: altan.1@osu.edu, Ph: + 1-614-292-5063
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Simulation For Forming

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CPF Simulation and Optimization of Metal Forming Processes

3. Tests to evaluate lubricants for stamping

4. Case studies in process simulation

Center for Precision Forming (CPF)

Stamping process as a system (e.g., the deep drawing process)

1. Workpiece material / Blank 2. Tooling 3. Interface 4. Deformation zone

5. Equipment 6. Part 7. Environment

Center for Precision Forming (CPF)

FE simulation is widely used in sheet metal forming as a virtual press to:

Successful application of FE simulation depends on:

Center for Precision Forming (CPF)

Determination of sheet material properties CPF

Engineering Stress-Strain Curve

True Stress-Strain Curve = Flow stress

Determination of sheet material properties CPF

Viscous medium Pressure transducer Stationary Punch

Determination of sheet material properties CPF

Bulge/ Dome height (h) Pressurized medium

Methodology to estimate material properties from VPB test, developed at CPF

Dome height (h)

Determination of sheet material properties CPF

10 inches (~ 250 mm)

4 inches (~ 100 mm)

Center for Precision Forming (CPF)

Determination of sheet material properties CPF

DP500 (Tensile test)

DP500 (Bulge test)

BH210 (Bulge test) BH 210 (Tensile test )

Center for Precision Forming (CPF)

Determination of sheet material properties CPF

Highest formability G , Most consistent F

Lower formability and inconsistent H

Applications of the bulge test

a. different incoming coils, and

Center for Precision Forming (CPF)

Stamping lubricants in the automotive industry

Decoiling and cutting

Stacking Blanks (dry or pre-oiled)

Deep Drawing + subsequent blanking operations

[Courtesy: M. Pfestorf, 2005, BMW ]

Stamping lubricants in the automotive industry

Decoiling / Recoiling with Lube coating by immersion or spraying

Decoiling and cutting

Deep Drawing + subsequent blanking operations

[Courtesy: M. Pfestorf, 2005, BMW ]

Test to evaluate lubricants for stamping

Deep drawn cup

Schematic of deep drawing tooling at CPF

Test to evaluate lubricants for stamping CPF

P b where = the frictional shear stress the coefficient of friction

Center for Precision Forming (CPF)

Test to evaluate lubricants for stamping CPF

Measurement of draw-in length, Ld, or perimeter of flange in a drawn cup

Center for Precision Forming (CPF)

Test to evaluate lubricants for stamping CPF

BHF = 50 tons Test speed = 65 mm/sec

Load-stroke curves of formed vs. fractured cups

Test to evaluate lubricants for stamping CPF

Center for Precision Forming (CPF)

Case studies in process simulation

Variation of BHF with stroke Springback control

Center for Precision Forming (CPF)