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Sheet Metal Stamping Simulation in the Real World
Sheet metal forming simulation can help tool and die designers to build tools right the first time, saving large amounts of time and money.
In this case, Malbern Engineering in South Africa had designed and fabricated a tool for a
new automotive project. During initial tryout, the process formed the part successfully.
However, once the tool was set for production, constant splits resulted.
Initially, a forming simulation of the current process was performed, to determine if the
splits were expected. The forming simulation result shows that indeed, the material is
predicted to split.
This is due to excessive thinning in the current process. "I decided to modify the 1st stage form tool as per your recommendation and as you can see from the photo's the proposal was successful.Thank you very much for your input."
Marco Smargiasso - Technical & Marketing Manager - Malben Engineering
A modification to the pre-form process was proposed, using sheet metal forming
simulation to engineer and develop the shape.Based on forming simulation and engineering development, an optimized pre-form shape was developed. The pre-form shape stretched the material evenly to ensure no excess thinning occurred.
Because of the engineered pre-form shape, the final shape formed successfully, without
splits and without excessive thinning.
The result is successful and robust. Using sheet metal forming simulation, it was verified that the final shape can be formed without further stretching and without consequential failure. The final form simply moves material, rather than adding more stretch. The simulation shows success and reality agrees.StampingSimulation.com are Sheet Metal Forming Simulation Experts. We are a specialist team of industry experienced Stamping Simulation Engineers.
About the Author
StampingSimulation.com is a worldwide team of specialist stamping simulation and sheet metal forming engineers. With resources across three continents (North America, Europe and Australasia) we are uniquely placed to offer fast turnaround times on all structural simulations, hydro forming simulations, ANSYS simulations and sheet metal stamping simulations.
