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Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
A Case Study ofA Case Study ofDie validation of fuel tank usingDie validation of fuel tank using
HyperForm 7.0HyperForm 7.0
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
ComponentComponent250 mm
350 mm
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Material PropertiesMaterial Properties
The material grade specified for this fuel tank is IFCS Material Properties specified by raw material supplier.
– Young’s Modulus, E : 215000 MPa– Poisson's ratio, nu : 0.26– Yield Stress, σ : 136MPa– Strain Hardening index, n: 0.21– Anisotropy ratio, rbar : 2.31– Strength coefficient, K : 12603 MPa
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Stages in simulationStages in simulation
Component
Feasibility Study
Die Face Design
Virtual Tryout Blank Optimizer
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Manufacturing Feasibility StudyManufacturing Feasibility Study
Mid surface Extracted
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Blank developedBlank developed
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Blank profile ( after adding Trimming allowance)Blank profile ( after adding Trimming allowance)
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Die FaceDie Face
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Virtual Tryout and Blank optimizationVirtual Tryout and Blank optimization
Tool build Process parameters specification
– Tool Motion– Tool Load– Draw bead location– Draw bead parameters– Lubrication
Blank Optimization
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Tool BuildTool Build
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Iteration 01Iteration 01
Process parameters:– Blank Holding Force : 40 Ton– Friction : 0.125– Draw beads : As per the table (next slide)
Blank shape:
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Draw beads ( Iteration 01)Draw beads ( Iteration 01)
BEADS DB1 DB2 DB3 DB4 DB5 DB6 DB7 DB8 DB9 DB10 DB11
DB Height 5 5 5 5 5 5 5 5 5 5 5
DB Rad 5 5 5 5 5 5 5 5 5 5 5
Sh Rad 4 4 4 4 4 4 4 4 4 4 4
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Formability plotFormability plot
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Next 10 iterationsNext 10 iterationsIT no. Input parameters Results
01 Blank holding force 50 tons, Draw bead parameters 5 x 5 x 4. Die entry radius R20.
Heavy wrinkles till bottom
02 Blank holding force increased to 80 tons.
Wrinkles reduced at straight edges only. Radius portion with heavy wrinkles.
03 Die entry radius at radius portion morphed to R17.5 using Hyper morph.
Wrinkles at radius portion reduced
04 Draw bead at straight portion tightened Wrinkling tendency at straight portion reduced.
05 Draw beads at radius portion tightened Resulted in crack
06 At radius profile radial draw beads added instead of straight.
Wrinkling tendency reduced but still persisted.
07 Draw bead at radial portions tightened Resulted in crack
08 Blank is chopped off to reduce blank holding force.
Crack vanished but little wrinkling tendency which can be avoided in tryout easily.
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Morphing Die Entry Radii locallyMorphing Die Entry Radii locally
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Morphing Die Entry Radii locallyMorphing Die Entry Radii locally
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Draw beads ( Iteration 02)Draw beads ( Iteration 02)
BEADS DB1 DB2 DB3 DB4 DB5 DB6 DB7 DB8 DB9 DB10 DB11
DB Height 5 5 3 5 5 5 2.5 5 5 5 5
DB Rad 5 5 3 5 5 5 5 5 5 5 5
Sh Rad 2.5 1.98 3 2.4 2.7 2.5 2 3.9 4 3.5 2.4
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Formability plotFormability plot
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Thinning plotThinning plot
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Finished PartFinished Part
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Our vision towards Our vision towards CAE…..CAE…..
1. To cover all forthcoming developments & existing 1. To cover all forthcoming developments & existing products products through CAD and CAE.through CAD and CAE.
2. Improve upon accuracy level of analysis.2. Improve upon accuracy level of analysis.
3. Cover other applications of analysis as well like 3. Cover other applications of analysis as well like PRODUCT PRODUCT OPTIMIZATION. OPTIMIZATION.
Supreme GroupSupreme GroupPeople Press, We ImpressPeople Press, We Impress
Quality FirstQuality First
TS-16949 Certified Co.
D-U-N-S Number86-246-4013
ISO/TS-16949:2002 Certified Co.ISO/TS-16949:2002 Certified Co.
Thank You….Thank You….
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