Skip to main content
SpringerLink
Log in

Expert system for simulation of metal sheet stamping

  • Original Article
  • Published:
Engineering with Computers Aims and scope Submit manuscript

Abstract

Stamping processes are frequently used in the automotive industry. In an attempt to reduce developing times and costs, conventional design and manufacturing procedures are being changed. Finite element simulations have proved to be a good help in the design and analysis of these processes. The main problem of these simulations is that they are quite difficult to perform and that there are several non-trivial questions that the user has to answer before achieving a good model. In this work, a new application has been designed. It combines the usability of a custom application with the power of such a tool as the finite element method. To design this application, a lot of questions regarding FEM simulation of stamping processes have been analyzed. The result is a methodology to automate simulations of stamping processes where the user does not need to have deep knowledge of the finite element software. Such methodology has been successfully employed in a Spanish manufacturing industry of automotive components.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8

Similar content being viewed by others

References

  1. Samuel M (2004) Numerical and experimental investigations of forming limit diagrams in metal sheets. J Mater Process Technol 153–154:424–431

    Article  Google Scholar 

  2. Makinouchi A (1996) Sheet metal forming simulation in industry. J Mater Process Technol 60:19–26

    Article  Google Scholar 

  3. Silva MB, Baptista RMSO, Martins PAF (2004) Stamping of automotive components: a numerical and experimental investigation. J Mater Process Technol 155–156:1489–1496

    Article  Google Scholar 

  4. Wei L, Yuying Y (2008) Multi-objective optimization of sheet metal forming process using Pareto-based genetic algorithm. J Mater Process Technol (in press), Corrected Proof. doi:10.1016/j.jmatprotec.2008.01.014

  5. LSTC (2006) LS-DYNA: user’s manual, version 971. LSTC, Livermore

  6. Gau J-T (1999) A study of the influence of the Bauschinger effect on springback in two-dimensional sheet metal forming. Center for Advanced Materials and Manufacturing of Automotive Components, The Ohio State University, Columbus, p 227

    Google Scholar 

  7. Narasimhan N, Lovell M (1999) Predicting springback in sheet metal forming: an explicit to implicit sequential solution procedure. Finite Elem Anal Des 33:29–42

    Article  MATH  Google Scholar 

  8. Buranathiti T, Cao J (2005) Numisheet2005 benchmark analysis on forming of an automotive underbody cross member: benchmark 2. In: Smith L, Zhang L, Wang C-T, Shi MF, Yoon J-W, Stoughton TB et al (eds) NUMISHEET 2005: proceedings of the 6th international conference and workshop on numerical simulation of 3D sheet metal forming process, AIP conference proceedings, Detroit. American Institute of Physics, Melville, pp 1113–1120

  9. Buranathiti T, Cao J (2005) Numisheet2005 benchmark analysis on forming of an automotive deck lid inner panel: benchmark 1. In: Smith L, Zhang L, Wang C-T, Shi MF, Yoon J-W, Stoughton TB et al (eds) NUMISHEET 2005: proceedings of the 6th international conference and workshop on numerical simulation of 3D sheet metal forming process, AIP conference proceedings, Detroit. American Institute of Physics, Melville, pp 996–1003

  10. Belytschko T, Liu WK, Moran B (2000) Non-linear finite elements for continua and structures. Wiley, New York

    Google Scholar 

  11. Firat M (2007) Computer-aided analysis and design of sheet metal forming processes: part I—the finite element modeling concepts. Mater Des 28:1298–1303

    Google Scholar 

  12. Firat M (2007) Computer-aided analysis and design of sheet metal forming processes: part II—deformation response modeling. Mater Des 28:1304–1310

    Google Scholar 

  13. Mattiasson K, Thilderkvist P, Strange A, Samuelson A (1995) Simulation of springback in sheet metal forming. In: Shen S-F, Dawson P (eds) Proceedings of the NUMIFORM’95 simulation of materials processing: theory, methods and applications. Cornell University, Ithaca, pp 115–124

  14. Micari F, Forcellese A, Fratini L, Gabrielli F, Alberti N (1997) Springback evaluation in fully 3-D sheet metal forming processes. CIRP Ann Manuf Technol 46:167–170

    Article  Google Scholar 

  15. Hallquist JO (1998) LS-DYNA theoretical manual. LSTC, Livermore

    Google Scholar 

  16. Cowper GR, Symonds PS (1958) Strain hardening and strain rate effects in the impact loading of cantilever beams. Brown University, Providence, p 46

    Google Scholar 

  17. Dietenberger M, Buyuk M, Kan C-D (2005) Development of a high strain-rate dependent vehicle model. In: Fourth German LS-DYNA Forum, 20–21 October 2005, Bamberg

  18. Jones N (1983) Structural aspects of ships collisions. In: Jones N, Wierzbicki T (eds) Structural crashworthiness. Butterworths, London, pp 308–337

    Google Scholar 

  19. Firat M (2007) U-channel forming analysis with an emphasis on springback deformation. Mater Des 28:147–154

    Google Scholar 

  20. Darendeliler H, Kaftanoglu B (1991) Deformation analysis of deep-drawing by a finite element method. CIRP Ann Manuf Technol 40:281–284

    Article  Google Scholar 

  21. Taylor L, Cao J, Karafillis AP, Boyce MC (1995) Numerical simulations of sheet-metal forming. J Mater Process Technol 50:168–179

    Article  Google Scholar 

  22. Tekkaya AE (2000) State of the art of simulation of sheet metal forming. J Mater Process Technol 103:14–22

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, University Carlos III of Madrid, Avenida de la Universidad, nº30, 28911, Leganés, Spain

    C. Álvarez-Caldas, A. Quesada, A. Gauchía & J. L. San Román

Authors
  1. C. Álvarez-Caldas
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. A. Quesada
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. Gauchía
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. J. L. San Román
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to C. Álvarez-Caldas.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Álvarez-Caldas, C., Quesada, A., Gauchía, A. et al. Expert system for simulation of metal sheet stamping. Engineering with Computers 25, 405–410 (2009). https://doi.org/10.1007/s00366-009-0137-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00366-009-0137-2

Keywords

Search

Navigation