Page 29 - MetalForming May 2010

ing new work. We can show a customer the FLD (forming-limit diagram) curves and identify potential problem areas, such as excess thinning in a corner or where extra relief may be required, before we get into die design and run into expensive surprises.”
Among the features offered by HyperForm are blank fitting and nest- ing, a die module that allows basic die- face design, an automated tool-builder module, virtual tryout, and die-struc- ture stress analysis and optimization. Radioss is an incremental forming solver that accurately predicts wrinkles and splits before die steels are cut and installed in the die, thus avoiding waste- ful and extra machining and tryout.
Asked to share one recent example of how the software helps, simulation tech- nician Dan Linderman describes a heat shield Aggressive recently tooled up.
“The part comprises a dual layer of aluminized steel,” says Linderman, “and its design is complex. It has a couple of complex features with a lot of shape to it. When we won the job, we initially designed it as a progressive strip. How- ever, during simulation it became evi- dent that we would have a problem car- rying the part in the die, due to the way in which it would have to be formed. Using the HyperForm simula- tion module, I tried several iterations to get the part to form properly, without folding over while also avoiding rips and tears. It quickly became clear to me and to the entire project team that we were going to have to scrap the idea of a progressive die and redesign the process with a transfer die.
“Recognizing the need to make the heat shield in a transfer die well before
any die steels were cut saved us and our customer a tremendous amount of man- hours,” Linderman continues. “We would have had a
major design change during the devel- opment process in the press.”
A Dramatic Improvement in Die-Build Efficiency
In addition to smarter upfront process planning and the benefits real- ized from early engineering, Aggressive also is able to leverage HyperForm’s simulation capabilities—via the Radioss/ Incremental virtual tryout module— to streamline the back end of its processes—die build and tryout.
“We’re going to the press with com-
pleted dies, rather than having to devel- op them in the press,” says Zuidema. “Better upfront engineering allows us to save a lot of time and money at the back end in machining, assembly and tryout. And, from a sales perspective, Greg and I realize a huge benefit from that, as we can move projects more effi- ciently and predictably through the shop and better schedule new work as it comes in.”
“Tryout is done on the computer screen while the tool steels are being cut,” adds Linderman. “And, as we’re machining form steels we’re wire-cut- ting trim steels, and bringing the whole project together for the diemaker. Time from conception to completion has been reduced by as much as 30 per- cent, and we’re routinely meeting cus- tomer requirements for early parts with short lead times.” MF
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METALFORMING / MAY 2010 27
This FLD plot shows areas of a part—a 0.7-mm steel roof reinforcement—that are deemed safe, in compression or where loose sheetmetal resides, as well as identifies possible areas of failure during stamping.