Page 14 - MetalForming-May-2018-issue

Tech Update
to build: binder spotting/bearing or gap; die clearances; bead shapes; panel-locat- ing/positioning pilots and gauges; tool kinematics; tonnage; form-pad bearing; trim tools and timing; etc.
numerical-control settings to ensure the accurate modeling of tool surfaces and sheetmetal.
validated in simulation, to produce a panel fully acceptable on all required formability metrics. The panel should be safe relative to forming limit; should meet edge- and surface-failure criteria; exhibit acceptable thinning and thickening; contain no foldovers and no buckles on seal surfaces; and offer the highest level of stretch achievable, as uniformly distributed on the panel as possible.
• Model material accurately using data from material tests; avoid generic and non-representative data.
• Apply scaling to the draw die; morph trim-die surfaces to locate the draw panel without crushing; and validate locating in simulation and adjust it until satisfactory.
• Respect and apply appropriate
• Develop and finalize a full process,
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MetalForming/May 2018
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• Finalize the developed blank outline and/or trim lines. After finalization, adjust the process as necessary to re-establish an acceptable panel.
• Measure springback in simulation, after each operation, with due diligence toward firm and repeatable panel posi- tioning that avoids sprung-panel distortion. Understand the evolution of springback from one operation to next.
• Recognize, using virtual tools, the mode of observed springback. Twist and/or oil-canning, and panel-sidewall curl cannot be compensated for, but must be addressed through process changes, or even product modifications, which sets the virtual-engineering process all the way back to step one. Likewise, springback magnitudes greater than 10 mm are dif- ficult to compensate for, requiring process/product adjustments. The sooner these potential issues are identified, the less expensive—in time and cost—it will be to mitigate these through appropriate countermeasures.
• Validate, using virtual tools, the robustness of the developed die and process to common uncontrollable param- eters in production—material, gauge, blank gauging, lube, etc. Are formability and, more importantly, springback out- comes narrowly repeatable despite all of that production ‘noise?’ If not, the ‘compensatability’ of dies is severely compromised. The die and process will need to be improved, leading toward robust outcomes, before investing effort in compensation.
• Last but not least, build the dies and process exactly as they have been engineered and validated in simulation. AutoForm Engineering USA, Inc.: www.autoform.com