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Finite element simulation of the manufacturing process chain of a sheet metal assembly
Linköping University, Department of Management and Engineering, Solid Mechanics. Linköping University, The Institute of Technology.
Linköping University, Department of Management and Engineering, Solid Mechanics. Linköping University, The Institute of Technology.
Linköping University, Department of Management and Engineering, Solid Mechanics. Linköping University, The Institute of Technology. Outokumpu Stainless AB, Avesta, Sweden.
2012 (English)In: Journal of Materials Processing Technology, ISSN 0924-0136, E-ISSN 1873-4774, Vol. 212, no 7, 1453-1462 p.Article in journal (Refereed) Published
Abstract [en]

An increasing number of components in automotive structures are today made from advanced high strength steel (AHSS). Since AHSS demonstrates more severe springback behaviour than ordinary mild steels, it requires more efforts to meet the design specification of the stamped parts. Consequently, the physical fine tuning of the die design and the stamping process can be time consuming. The trial-and-error development process may be shortened by replacing most of the physical try-outs with finite element (FE) simulations of the forming process, including the springback behaviour. Still it can be hard to identify when a stamped part will lead to an acceptable assembly with respect to the geometry and the residual stress state. In part since the assembling process itself will distort the components. To resolve this matter it is here proposed to extend the FE-simulation of the stamping process, to also include the first level sub-assembly stage. In this study a methodology of sequentially simulating each step in the manufacturing process of an assembly is proposed. Each step of the proposed methodology is described, and a validation of the prediction capabilities is performed by comparing with a physically manufactured assembly. The assembly is composed of three sheet metal components made from DP600 steel which are joined by spot welding. The components are designed to exhibit severe springback behaviour in order to put both the forming and subsequent assembling simulations to the test. The work presented here demonstrates that by using virtual prototyping it is possible to predict the final shape of an assembled structure.

Place, publisher, year, edition, pages
Elsevier, 2012. Vol. 212, no 7, 1453-1462 p.
Keyword [en]
Finite element simulation, Assembly, Sheet metal, Forming, Springback
National Category
Engineering and Technology
Identifiers
URN: urn:nbn:se:liu:diva-77853DOI: 10.1016/j.jmatprotec.2012.02.012ISI: 000304020800001OAI: oai:DiVA.org:liu-77853DiVA: diva2:529734
Note

Funding Agencies|Swedish foundation for strategic research||ProViking programme||

Available from: 2012-05-31 Created: 2012-05-31 Last updated: 2017-12-07Bibliographically approved
In thesis
1. Simulation of the Manufacturing Process of Sheet Metal Assemblies
Open this publication in new window or tab >>Simulation of the Manufacturing Process of Sheet Metal Assemblies
2012 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The increased complexity of products and narrow lead times for product development have intensified the use of virtual prototyping, also called simulation-based design. The simulation of each individual manufacturing process is an important part of product development, However it is also necessary to study the complete sequences of manufacturing processes. By studying the complete sequence, the properties of the entire manufacturing process and the final product can be evaluated. The quality of the results from each individual process simulation is improved by supplying initial conditions that closer match the reality. Thus, greater benefits can be gained from using simulation as a tool within process and product development.

In this thesis the manufacturing process chain of a sheet metal assembly is studied. A methodology of sequentially simulating each step in the manufacturing process of the assembly is proposed. Each step of the proposed methodology is described, and a validation of the prediction capabilities is performed by comparisons with results from a physically manufactured assembly. Furthermore a simulation based sensitivity study is performed in order to investigate the influence of the forming history on the predictions of the assembly properties. In the study, several simulations of the assembly stage are performed in which different types of forming histories are retained from the forming stage.

This study demonstrates that it is possible to predict the final shape of an assembled structure by using virtual prototyping. It is found that the most influential factor from the forming stage is the residual stress state. Especially for components with a more complex geometry in which large residual stresses can be retained. It is also shown that it is important for the quality of the prediction to retain as much information as possible from the previous manufacturing steps. The proposed simulation procedure is a useful tool during product development phases in order to evaluate the properties of both the manufacturing processes and of the final assembly.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2012. 41 p.
Series
Linköping Studies in Science and Technology. Thesis, ISSN 0280-7971 ; 1532
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-78770 (URN)LIU-TEK-LIC-2012:17 (Local ID)978-91-7519-877-4 (ISBN)LIU-TEK-LIC-2012:17 (Archive number)LIU-TEK-LIC-2012:17 (OAI)
Presentation
2012-06-15, Sal A35, Hus A, Campus Valla, Linköpings universitet, Linköping, 10:15 (English)
Opponent
Supervisors
Available from: 2012-06-20 Created: 2012-06-20 Last updated: 2012-06-20Bibliographically approved
2. Finite Element Analysis of Sheet Metal Assemblies: Prediction of Product Performance Considering the Manufacturing Process
Open this publication in new window or tab >>Finite Element Analysis of Sheet Metal Assemblies: Prediction of Product Performance Considering the Manufacturing Process
2014 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

This thesis concerns the development of methodologies to be used to simulate complete manufacturing chains of sheet components and the study of how different mechanical properties propagate and influence succeeding component performance.

Since sheet metal assemblies are a major constituent of a wide range of products it is vital to develop methodologies that enable detailed evaluation of assembly designs and manufacturing processes. The manufacturing process influences several key aspects of a sheet metal assembly, aspects such as shape fulfilment, variation and risk of material failure.

Developments in computer-aided engineering and computational resources have made simulation-based process and product development efficient and useful since it allows for detailed, rapid evaluation of the capabilities and qualities of both process and product. Simulations of individual manufacturing processes are useful, but greater benefits can be gained by studying the complete sequence of a product's manufacturing processes. This enables evaluation of the entire manufacturing process chain, as well as the final product. Moreover, the accuracy of each individual manufacturing process simulation is improved by establishing appropriate initial conditions, including inherited material properties.

In this thesis, a methodology of sequentially simulating each step in the manufacturing process of a sheet metal assembly is presented. The methodology is thoroughly studied using different application examples with experimental validation. The importance of information transfer between all simulation steps is also studied. Furthermore, the methodology is used as the foundation of a new approach to investigate the variation of mechanical properties in a sheet metal assembly. The multi-stage manufacturing process of the assembly is segmented, and stochastic analyses of each stage is performed and coupled to the succeeding stage in order to predict the assembly's final variation in properties.

Two additional studies are presented where the methodology of chaining manufacturing processes is utilised. The influence of the dual phase microstructure on non-linear strain recovery is investigated using a micromechanical approach that considers the annealing process chain. It is vital to understand the non-linear strain recovery in order to improve springback prediction. In addition, the prediction of fracture in a dual phase steel subjected to non-linear straining is studied by simulating the manufacturing chain and subsequent stretch test of a sheet metal component.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2014. 47 p.
Series
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 1605
National Category
Metallurgy and Metallic Materials Applied Mechanics
Identifiers
urn:nbn:se:liu:diva-106637 (URN)10.3384/diss.diva-106637 (DOI)978-91-7519-300-7 (ISBN)
Public defence
2014-06-05, C3, Hus C, Campus Valla, Linköpings universitet, Linköping, 10:15 (Swedish)
Opponent
Supervisors
Available from: 2014-05-16 Created: 2014-05-16 Last updated: 2014-05-23Bibliographically approved

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Govik, AlexanderNilsson, LarsgunnarMoshfegh, Ramin

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