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Considering Tool and Press Elasticity within the Forming Simulation and Experimental Validation

There is an increasing demand for car body parts made of high strength steels nowadays. The prediction of forces needed for stamping these parts is very difficult due to elastic deformations of the tools and presses. These deformations cause a gap between the tools at the end of the stroke if the production press has different elastic properties than the try-out press. The pressed piece is not sufficiently formed unless an additional force is added to close the gap. To predict the magnitude of the total force needed the forming simulation using elastic tools, instead of standard rigid tools, has to be implemented. The disadvantage of this calculation method is a very high CPU time. To reduce the CPU time, several available speed-up methods are tested and checked for reliability on simplified models. The two most suitable are chosen after the analysis of results, and applied on the more complicated real case model where only the punch is considered elastic. After analyzing these results, the best method, called Tied Contact (TC), is chosen for the real case complete model application on a side member of the VW Tiguan and the results are compared to the experimental data.

application/pdf C-I-02.pdf — 1.0 MB