Consideration of uncertainties in forming simulation using HyperWorks

In the automotive industry, the lightweight is an increasingly important issue. This leads to the increased use of high strength steels and aluminum. These materials decrease the process capability of forming of many automotive components than conventional materials. It becomes more difficult to predict the feasibility of CAE methods. One starting point is the consideration of uncertainties in the forming simulation. These uncertainties include fluctuations in the material quality (diligence curve, anisotropy, ...) and physical parameters (friction, blank holder force, ...). This can be examined using a Design of Experiments analysis(DoE) which is integrated inHyperStudy. A further approach is the use of additional failure criteria than the traditional FLC and thinning limits. As and when certain critical areas are found countermeasurescan be taken in time. These measures may include: change of forminggeometry or the whole process, or even a design change of the component.

 

The Author

Markus Reinert
DTE Werkzeugtechnik GmbH & Co. KG
Process Planner