PAM-OPT™/PAM-SOLID™: Optimization of Transport Vehicle Crash and Safety Design and Forming Processes

1998 ◽  
Author(s):  
E. Haug ◽  
P. Guyon
Keyword(s):  
Sheet Metal Forming ◽  
Process Simulation ◽  
Metal Forming ◽  
Paper Briefly ◽  
Fast Solvers ◽  
Vehicle Crash ◽  
Safety Design ◽  
Transport Vehicle ◽  
Flow Charts ◽  
Vehicle Crashworthiness

Abstract Dynamic simulation solver codes are now extensively used by industry for the design verification of vehicle crashworthiness and for the process simulation of sheet metal forming. The logical next step is to use these by now proven codes for the optimization of the vehicle crash design and of metal forming processes. A step towards this goal has been taken by PSI, and an optimization code, PAM-OPT™, has been written for calling dynamic FE codes of the PAM-SOLID™ family in design and process optimization loops. The code interacts with the user via input, signalling and output files and it calls an interface that interacts with the FE solvers. The paper briefly outlines the properties and various flow charts of the optimizer, depending on single or multiple solvers used in the loop, single or parallel calls and fast solvers. Then the paper reports various applications of PAM-OPT™ in conjunction with the PAM-SFE™, PAM-CRASH™, PAM-SAFE™ and PAM-STAMP™ solvers. An outlook on how to replace the user-written interface with a general keyword-driven interface concludes the paper.

Numerical Simulation and Process Optimization for Multi-Stage Forming of Wheel Centre Disc

2011 ◽  
Vol 189-193 ◽  
pp. 2770-2774
Author(s):  
Gan Wei Cai ◽  
Xi Yong Xu ◽  
Zhan Guang Zheng ◽  
Zhuan Zhang ◽  
Du Chao Wu
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Process Simulation ◽  
Metal Forming ◽  
Forming Process ◽  
Stage Number ◽  
Forming Quality ◽  
Steel Wheel ◽  
Multi Stage ◽  
Forming Characteristics

The steel wheel centre discs are usually stamped by multi-stage sheet metal forming. The stage number and the content of every stage decide if the structure-pieces can be formed successfully and the final forming quality. In this paper, the forming characteristics of wheel centre disc were analyzed firstly and the reasonable two-stage stamping scheme of drawing and inverse-drawing are adopted. The numerical simulations of multi-stage stamping process are performed and connected together through deformation transmission. By means of FLD and changes of sheet metal chickness, the formability is analyzed and the forming process is optimized. The feasibility of multi-stage forming process simulation and the validity of the optimized scheme were verified by stamping in practice.

Reverse Engineering for Spotting of Sheet Metal Forming Parts

2010 ◽  
Author(s):  
Christine Schoene ◽  
Ralph Stelzer ◽  
Ulf Schmidt ◽  
Dietmar Suesse
Keyword(s):  
Reverse Engineering ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Process Simulation ◽  
Metal Forming ◽  
Process Engineering ◽  
Forming Process ◽  
Scientific Analysis ◽  
Measurement And Analysis ◽  
Optimisation Algorithms

The paper elucidates how to connect forming process simulation with innovative measurement- and analysis equipment thereby taking into account the machine influences. Reverse Engineering use 3D-Scanning data of sheet metal forming dies. Following this paradigm, the models simulation relies on are refined, and spotting of forming dies is subjected to a scientific analysis. That means, that with Reverse Engineering, “extended process engineering” is verified at the real spotting procedure, the comparison of simulation- and measuring results is used to evaluate how close the investigated models are to reality, extending the optimisation algorithms used for springback compensation to die spotting, the modification of the die topology will be carried out automatically thanks to new software functions.

A New Mesh Variables Mapping Method for Vehicle Crash Simulation with Considering Sheet Forming Effects

2011 ◽  
Vol 338 ◽  
pp. 245-250 ◽  
Author(s):  
Zhou Li ◽  
Xu Jing Yang
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Simulation Analysis ◽  
Thickness Distribution ◽  
Mapping Method ◽  
Vehicle Body ◽  
Element Analysis ◽  
Crash Simulation ◽  
Vehicle Crash

In finite element analysis for vehicle body components, there are different meshes between sheet metal forming and crashworthiness analysis. In order to transfer mesh variables between different mesh models, a new mapping method for mesh variables is proposed in this study based on an inverse isoparametric mapping. In this method, the mesh variables, such as thickness distribution, stress and strain, are mapped by accurately positioning crash model’s nodes to transfer data from the sheet metal forming model to crash model. As an example, this approach was applied to the crash simulation analysis for a vehicle front bumper bar. The results showed that this method allows to precisely transfer mesh variables from sheet metal forming analysis to crash simulation analysis with considering the forming effects. The efficiency and accuracy are thus improved for vehicle crash simulation with this approach.

ИССЛЕДОВАНИЕ ТОЧНОСТИ ДЕТАЛЕЙ, ПОЛУЧАЕМЫХ ПРИ РАЗДЕЛИТЕЛЬНЫХ ОПЕРАЦИЯХ В ПЕРЕНАЛАЖИВАЕМЫХ ШТАМПАХ

2018 ◽  
pp. 52-63
Author(s):  
Е. А. Фролов ◽  
В. В. Агарков ◽  
С. И. Кравченко ◽  
С. Г. Ясько
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Balance Method ◽  
Experiment Planning ◽  
Practical Recommendations

To determine the accuracy of the readjustable punches for separating operations (perforation + punching out) of sheet-metal forming, the accuracy parameters were analyzed using the random balance method using the method of experiment planning. Analytical dependencies are obtained to determine the values of deviation of the outer and inner contour dimensions of perforated and punched out sheet parts. From the dependencies obtained, it is possible to estimate and predict the value of deviation in the dimensions of the resulting part at any time during the operation of the punch. Practical recommendations on the calculation of the actuating dimensions of the working elements (stamping punch, matrix) of readjustable punches are offered.

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