3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

April 14, 2006 Naomichi Mori, Inter-regional co-ordinator of 3DS project

3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

History of the project

1994
Feasibility study Phase I Phase II

1997

2000

2003

2005

Japanese partners started feasibility study

Kicked off Phase I

End of Phase I Kicked off Phase II

End of Phase II

3DS project was endorsed by IMS-ISC

1994. April 1997. May 2000. January 2000 February 2000. March 2000. September 2001. April 2001. September 2002. April 2002. December 2003. March 2003. April 2005. December

Japanese partners started feasibility study Endorsed by IMS-ISC as international collaboration project EU partners are endorsed by EU commission Kicked off Phase I Kick-off meeting in Isehara, Japan(Amada Metrecs) The second inter-regional meeting in Sindelfingen, Germany (DaimlerChrysler) The third inter-regional meeting in Tokyo and Niigata(Nissan and Tsubamex) The fourth inter-regional meeting in Porto, Portugal (FEUP, FCTUC) The fifth inter-regional meeting in Sendai, Japan (Tohoku University) The sixth inter-regional meeting in Paris, France (Arcelor and Renault) End of Phase I Kicked off Phase II End of Phase II

3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

Consortium composition

Canada FTI

EU JAPAN

SWISS

Swiss Autoform EU Cockerill-Sambre(Belgium) ESI (France) Arcelor (France) Renault Automobiles(France) Pechiney CRV (France) DaimlerChrysler (Germany) Volvo Car Corporation (Sweden) LPMTM-CNRS(France) University of Coimbra (Portugal) University of Porto (Portugal)

Japan Amada Metrecs Famotik Nissan Motor Press Kogyo Tsubamex CIMPTOPS Fukushima National college of Technology Osaka Institute of Technology RIKEN The University of Tokyo Tokyo University of Agriculture and Technology Tohoku University

*This consortium composition includes all of partners from Phase I to Phase II.
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3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

Background of the project

Change Change in in manufacturing manufacturing environment environment

Technological Technological requirement requirement in in the the manufacturing manufacturing process process fields fields

1. Speedy development of the high-value added products 2. Quick delivery and cost reduction 3. Response to diversified customer needs

1. Quality improvement and cost reduction 2. Enhancement of quality 3. Response to processing material changes due to weight reduction

The above situation is same with die manufacturing of core industry Stamping die 3DS project Plastic die Target of

3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

Outline of the project

Goal of the project Effects

To realize Press forming defect evaluation system, which is capable of aiding the designing of a sheet-metal stamping die and its try-out on a computer, eliminating thus the costly and time-consuming try-out on site as currently practiced

1. 1.Reduction Reductionof of time timeand andcost costduring duringthe the design and tryout design and tryout 2. Reducing 2. Reducingtime timeto tomarket market 3. Systematizing a system 3. Systematizing a systemfrom fromdie diedesign designto to production allows to reutilize empirical production allows to reutilize empirical knowledge knowledgeand andtechnique techniqueof ofskilled skilledengineers engineers

Main subjects

Press forming defect evaluation system

1. To develop the definition and the quantitative evaluation method of geometrical forming defects 2. Constructing a set of standard benchmark test problems 3. To develop guidelines for constructing appropriate elasto-plastic constitutive models

CAD data

FEM data

Measurement data

Example of evaluating forming defects Local shape characterization display

3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

Current status of stamping die manufacturing

Designed products Simulation process
Sheet metal forming simulation Part design Die face design Modification Investigation Confirmation Modification Investigation Empirical data base

Tryout process

Simulated products

Die design NC Die processing Modification Tryout

Confirmation

Investigation

Mass production (Trial production)

Formed products

3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

Technological requirements in the stamping die manufacturing

Digital DATA

Designed products Tryout process

Part design Die face design Empirical data base Modification Confirmation Investigation

Simulation process
Sheet metal forming simulation

Modification Investigation

Die design NC Die processing

Digital DATA
Tryout

Modification

Confirmation

Investigation

Formed products

Mass production (Trial production)

3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

Outline of the research contents

Research Research themes: themes:

Research and development of basic technology to construct press forming die design support system

1. Development of user-friendly methods and software for evaluating forming defects.(WP1) 2. Evaluation and improvement of the ability of numerical software to predict forming defects. (WP2) 3. Selection of appropriate physical models and their identification. (WP3)

3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

WP1: Development of methods and software for evaluating forming defects)

Goal of the WP1: Development of the definition and the quantitative evaluation method of geometrical forming defects Development of the graphical software library to construct a forming defect evaluation processor system for illustrating defined forming defects quantitatively on the computer.

Main results of the WP1 The quantitative evaluation method of forming defects Software called Evaluation Processor, allowing an objective comparison of CAD definition, CAE calculations and experimental measurements on press formed parts (for benchmark test). The processor system provided an important tool for comparing experimental and simulation results of the benchmark problems.

3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

WP2: Evaluation of the ability of numerical software to predict forming defects

Goal of the WP2: Constructing a set of standard benchmark test problems which enabled us to evaluate the ability of a code to predict forming defects such as wrinkle, geometrical inaccuracy due to springback, surface deflection and so on. In the benchmark problems, reference experimental data play a very important role and international cooperation is indispensable to obtain well-examined worldwide standard experimental data.

Main results of the WP2 WP2 provided a reliable experimental data base and the improvement of the available software for predicting forming defects.

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3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

WP3:Selection of appropriate physical models and their identification

Goal of the WP3: Development of guidelines for constructing appropriate elasto-plastic constitutive models for different steel and aluminum sheets, and realistic friction models Development of the standard material and friction tests to find out the parameters used in the computer simulation

Main results of the WP3 WP3 provided a selection of material and friction models that are appropriate for predicting forming defects by numerical simulations.

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3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

Each research theme and its relationship

WP3/TASK2 WP3/TASK1 Selection and identification of elastoplastic and friction models for the materials and tools used in the benchmarks WP3/TASK3 Verification of the appropriateness of the selected physical models for predicting forming defects WP2/TASK4 Evaluation and improvement of the ability of numerical methods to predict forming defects WP2/TASK2 Carrying out the experimental benchmark tests and geometrical measurement of the parts

Precision improvement Precision improvement (Physical model) (Physical model)

Selection of effective numerical algorithms for implementing the physical models into numerical code WP2/TASK3 Standardization of input-output data for benchmark tests

Selection of appropriate Selection of appropriate numerical code for numerical code for predicting each forming predicting each forming defect defect

WP1/TASK4

New forming evaluation New forming evaluation method method Springback Springback

WP2/TASK1

Development of a defect evaluation processor

Definition of a set of experimental benchmark tests for evaluating numerical methods WP1/TASK2 Definition of forming defects WP1/TASK1 Standardization of object data and necessary conditions for data acquisition WP1/TASK3 Characterization and evaluation of forming defects 12

Surface deflection Surface deflection

3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

Administrative structure
ICP Inter-regional meeting RCP Regional meeting
Schedule, communication and document management

Technical Committee Working group

WP3
Research of physical model

WP1
Press forming Evaluation processor

GroupWare
WP2 Benchmark tests

Research activities
Internet

Data server
Investigation program for forming evaluation method Investigation of new evaluation method

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3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

Conclusion
Management aspects: There was always a perfect cooperation between partners and no conflict Some friendships was established between some peoples of the consortium and the relationship facilitate inter-regional collaboration research We had a great pleasure to work with our European partners From now on, the good relationship established in this project will continue Technical aspects: Even though we faced a lot of difficulties, 3DS project has successfully fulfilled the major part of the tasks Quantitative evaluation method and the software called Evaluation Processor was developed Significant number of benchmarks were successfully conducted Numerical codes were improved in terms of fastness and accuracy The specific mechanical tests aiming at improvement of the material representation were successfully done

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3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

3DS Consortium Partners

Fourth inter-regional meeting in Porto, Portugal

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3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

3DS Consortium Partners

Fifth inter-regional meeting in Sendai, Japan

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3DS / Digital Die Design System

Development of basic technology for integrated forming CAE system

Finally..

I would like to take this opportunity to thank all the people of IMS for everything done for 3DS over the years. Especially, I would like to extend my appreciation to IMS Japan for supporting and helping 3DS project activities.

Naomichi Mori, Inter-regional co-ordinator of 3DS

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