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Simulation, modelling and validation software
News Release from: StampingSimulation.com | Subject: Multistage simulation services
Edited by the Engineeringtalk Editorial
Team on 16 November 2006
Multistage forming simulations
What happens if your part is unlikely to be successfully formed in a single stage? What if you want to see what would happen if you tried to form it in a single process?
Obviously, the design of the part is all important here If by design, the part is fully open (ie no undercutting) but a rather complicated shape that better judgment suggests would be impossible to form in a singe hit, then it is worthwhile to simulate a single stage form to see what might happen
This article was originally published on Engineeringtalk on 14 Aug 2006 at 8.00am (UK)
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The basic steps of die face design
When using a tool like Dynaform to design die faces, with the intent of simulating the design for verification, there is a basic path or set of steps that are used to end up with a die face design.
This is what forming simulation is all about.
It is the "try and see method" BUT without cutting tool steel.
The "guestimation" is low risk because the simulation is done in the virtual environment meaning the cost is only a fraction of what a proto tool (or worse still) a full production tool might cost.
Further reading
CAD models crucial in stamping simulation
The quality of CAD modelling is important, according to StampingSimulation.com.
Forming simulation as a tool
How accurate is forming simulation? This is the question which most toolmakers ask when the use of forming simulation is suggested.
Then why simulate a single stage form that is intuitively going to fail?.
Isn't this just wasting time and money (although only a small amount)?.
If you have a part like this then we will simulate the form in a single stage whether you request it or not.
The reason being, the results of such a single stage analysis provides valuable insight into what the requirements are for a preform or predraw tool.
A single hit simulation shows where the material is moving and in what directions it is straining, so that a pre-draw tool can be designed.
The aim is to ensure that the material limits are not reached by the time the final shape is stamped into the part.
For example, a part's geometry might be such that it does not allow material to evenly flow from the blank into the areas where it is needed most.
In this case, a predraw stage would be designed that is a smooth, flowing surface which might over-draw the part and leave excess material available to "hit back down" in the final form tool.
Of course, many who are toolmakers have experienced this before but have you ever seen it done virtually, without any of the expense of building a tool?.
OK then, what about parts that physically cannot be formed in a single stage because of undercuts or negative angled flanges?.
In these cases, the geometry is "unfolded" and undercut analysis is performed.
Once all undercuts are removed, the part can be considered for single or multi stage forming.
Of course, a final flange or bend stage is needed at the end to put the geometry back in that was unfolded in the first step.
In summary, forming simulation can tackle any multi stage forming job.
Naturally, the time to do so is more substantial than that taken to perform a single stage form simulation and hence, the cost to perform multiple stage simulations is scaled accordingly.
But we ask you this: Can your business afford to develop difficult parts the "old" way?.
StampingSimulation.com offers two affordable multistage simulation services priced from just US $495.
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