Metal Forming

Seminar: Grundlagen der Blechumformung

The component design, the material and the forming process influence function, quality, formability and costs of a sheet metal component. Therefore it is important for part designers as well as FE analysts, to understand the basics of the sheet metals. Especially for FEA the effect of forming (work hardening, thinning/thickenning, residual stress,...) on the part performance (strength, stiffness, modal frequencies etc.) is presented.

• Basics of the forming
  • Elastic and plastic deformations
  • stress strain curves, plastic anisotropy and material models for forming simulation
  • strain hardening, bake hardening, change of Youngs modulus
  • Failure in sheet metal failure (splitting, wrinkling)
  • forming limit diagram
  • geometric deviation and springback

• forming simulation
  • Influence of thickness alteration and hardening on the structure behavior
  • Influence of geometry deviations on the structure behavior
  • Influence of residual stress and Youngs Modulus change

• Effect of the forming process on part properties
  • forming processes
  • Effect of the forming process on the component qualities
  • Influence of the process conditions (tool forces, friction)
  • Influence of the tool geometry

• Forming simulation
  • Calculation procedures and typical application areas
  • Prerequisites and input data for the forming stimulation
  • Computation with component geometries
  • Calculation with tool geometries
  • Postprocessing and results interpretation

• Mapping of forming results
  • Mapping of forming results to new meshes
  • Adding the result mapping to the simulation process

  

The participants learn the basics of the plastic deformation of metals. The processes in the material are expounded and the different distortion behaviors of the sheet metal materials are shown. The formability and related problems such as thinning, formation of wrinkles and geometric deviation like tolerances and springback are represented. The influence on the final product properties, in particular by change of thickness and hardening, are described. In the second part forming processes (tools, process conditions such as forces, friction etc.) are described, as the process affects the part properties.
Possibilities for the simulation of forming processes are discussed together with therequired input. This is related to the coupling of forming simulation and structural analysis. Finally, hints regarding the practical usage of the coupling forming - structural analysis are given.