Achieving a sheet metal part within dimensional tolerance without the need for tool recutting is the ultimate goal of every forming simulation. Several key factors are essential to reach this goal: an accurate forming simulation with precise material descriptions, correct friction val-ues, and an accurate binder model to determine the correct material flow and stress state of the part after forming. Additionally, an accurate springback calculation is required, considering the part clamped in the measurement device and the effect of gravity. With these results the new tool geometry has to be determined to compensate the springback of the sheet metal part.
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Mesh adaptivity refines the blank mesh as needed in stamping simulations. Users do not need to anticipate where a dense mesh will be required. Despite its universal use, it demands significant effort due to serialization and the need to carry a dense mesh through subsequent iterations. In-Core adaptivity and Mesh fusion assist the solver in conserving effort, thereby enhancing performance. This paper will demonstrate best practices for utilizing In-Core adaptivity and Mesh fusion in Ansys Forming through practical cases. In addition, for different model, we should find an optimum number of CPUs to run the job. Beyond this number, the scalability will not see any obvious improvements.
Tool wear is a common problem in the manufacturing process of heat exchanger plates. The shape of HP changes due to tool wear, causing issues in subsequent processes such as welding, brazing, and assembling. In this paper, a simulation model of heat exchanger plates using Ansys Forming® is created to predict tool wear. It provides guidance for the shape design of heat exchanger plates, aiding in the planning of tool repair and replacement.
Numerical simulations are increasingly used to design and optimize sheet metal forming manufacturing processes [1]. ANSYS FORMING® [2] offers a comprehensive, process-centric solution for metal stamping simulation. It simplifies the setup of multi-stage forming simulations, making it accessible and efficient for users. Relying on the ANSYS LS-DYNA® multiphysics solver, the platform offers easy job submission and monitoring. The interface integrates post-processing capabilities that allow for detailed analysis of the resulting part.
Simulation of sheet metal forming has long been a fundamental application of ANSYS LS-DYNA, predominantly relying on shell elements under a plane stress assumption. While effective in many cases, situations arise where a full 3D representation becomes imperative, particularly when modelling thicker sheets or parts with tight radii. However, transitioning from shell to solid elements poses immediate challenges related to e.g. element size and the simulation model size.
Highly Automated Springback Compensation of the Draw Die©