Page 26 - MetalForming-Apr-2018-issue

Die-Design and Simulation
unique concept and maximize its chance of success, Penn United turned to the Deform system for bulk-metal- forming process simulation, developed by Scientific Forming Technologies Corp., Columbus, OH. The team mod- eled the proposed progressive-stamping process in the Deform-3D multiple- operation environment. Stud formation would take place across three forming operations, and the process design
incorporated tool movements in three directions.
Simulations allowed Penn United to predict how blank geometry and tooling design impacted the finished part. Toolmakers optimized die fill, once the customer identified allowable underfill areas of the part. Simulation also allowed Penn United to predict the risk of cracking using the damage- state variable. Engineers knew the
Fig. 3—A completed part confirms simu- lation predictions and leads to long-term successful part production.
material’s critical damage value, at which cracking and other defects would be likely, based on historical data. Thus, they maintained a com- fortable factor of safety and minimized the risk of cracking.
In addition to technical benefits, simulation output allowed Penn United to clearly and concisely communicate results to its customer, with process design established scientifically, rather than through a gut feel. The customer analyzed this feedback, particularly the anticipated die fill, to determine viability of the solution.
Positive Deform simulation results (Fig. 2) convinced the customer to move forward with development and testing. Penn United manufactured single-hit tooling and produced a small batch of prototypes, and the final parts (Fig. 3) correlated well with simulation predictions.
Subsequent product testing of the link revealed the customer’s desire for slightly more die fill, so further refine- ment of the stamping process accom- modated this change. Toolmakers used simulations and tests on hard tooling to optimize the updated design, which now included a fourth forming opera- tion, and subsequently manufactured a progressive-stamping die for high- volume production. Penn United, reporting long-term success in running this job, credits Deform for developing and proving out the company’s ‘out- side-the-box’ concept.
Scientific Forming Technologies Corp.: www.deform.com MF
24 MetalForming/April 2018
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