PAM-FORM

Material Definition :
- Odgen Model Order 2 W :
=
Norder
∑
i =1
αi αi β i αi λ1 + λ2 + λ3 − 3 αi
(
)
6.10-5)
Mooney-Rivlin Model (α1=2, β1=6.10-6, α2=-2, β2=- Thickness e=9mm & ρ=970 kg m-3
Whirlpool
Optimisation of material usage
FLATTENING
Why VW simulates gas tank forming?
§ Fuel tank must not break during a crash event
§ Need to include gas tank in the car crash simulations § Need for an accurate description of the thickness variations § Old VW method: § Cut 60 strips in the actual tank and measure the thickness § Enter these 60 thicknesses in a PAM-CRASH model § Current Method: § Perform a PAM-FORM simulation § Read the computed thickness field over the full gas tank and
the Numerical Simulation § Thermoforming § Stretching-Blowing § Extrusion-Blowing § Some Insight in the Numerical Modeling § The working Step by Step Method
§ Heat Transfer through Mechanical Contact
§ Necessary Material data
§ Surface Heat Transfer Coefficient or § Thermal Conductivity
§ Specific Friction Treatment § Coulomb Friction § Temperature dependency § Mixed Dry-Viscous models § 2 Possible Specific Material laws § Hyper-elastic Ogden Model (no strain rate effects) § Thermo-Visco-Elastic G'Sell Model (strain rate effects)
PLASTIC PARTS FORMING EXAMPLES
§FUEL TANKS §DASHBOARDS §DOOR PANELS
§ APPLIANCES § FOOD PACKAGING
PLASTIC FORMING (1/3)
§ THERMOFORMING
Heating Pressure
Punch Moves
§ PROCESS OPTIMIZATION
§ Sheet/Tools Temperature Selection § Restraining Systems Definition § Process Kinematics § Sheet Thickness § Material Selection (tooling & plastic) § OUTLOOK § Pre-Heating / Cooling steps § Process Induced Material Properties
§ See also Arcelik Europam 2002 presentation
(includes a benchmark against other commercial software); less than 6% error.
PLASTIC FORMING WHY SIMULATE?
Lower tool
ቤተ መጻሕፍቲ ባይዱ
Parison evolution
Film
Initial state
Tan k
Etape 1 : Closing stage
Etape 2 : Holding & Forming stage
Etape 3 : Blowing stage
TANK (Results)
Max.princ. S strain o.thickness
§ Starting Point = PAM-STAMP for sheet metal stamping simulation § Thermal Capabilities § Heat Conduction for Shell Elements
§ Necessary Material data
§ Specific Heat (possibly as a function of temperature) and § Thermal Conductivity
FORMING PRESSURE
0,012 0,01 0,008 0,006 0,004 0,002 0 0 -0,002 -0,004 -0,006 Time [1/10 s] 1 2 3 4 5 6
Vacuum
Pressure [MPa]
§ STRETCHING-BLOWING
PLASTIC FORMING (2/3)
DEMO EXAMPLES § The remaining slides describes two test
cases which are are delivered as examples with PAM-FORM
§ Gas tank § Yoghurt Pot
TANK (Material Type 122 : Odgen Model)
Composite Forming Example from Airbus UK (3/4)
Laminate Definition
Airbus UK Ltd.
Forming Steps
Composite Forming Example from Airbus UK(4/4)
Actual part:
Mecaplast
CAR INTERIORS FORMING
• Dashboard, Car carpet, Car seat covering, Panel Covering, Liners, etc
MECAPLAST
PAM-FORM for PLASTIC SHEETS
Whirlpool
ARCELIK (TU) DELPHI(USA) VISTEON(F) VW(D) WHIRLPOOL (I) 1 Plastic Producer
(Crystallization, Anisotropy,…) § Value Chain: Use of Forming results to Improve the Design Simulation (eg: failure model in plastic based on the same model as the forming model)
Min/Max: -0.17 /0.69
Min/Max: -0.03 /1.14
POT
Material Definition :
- Thickness e=1.3mm, ρ=1050 kg m-3, ν= 0.37, E : 1.7 kN/mm2 - G´Shell Model [k(T), m(T), h(T), w(T)] - Cp=2000J/kg.K and Thermal Conductivity
§ Other results:
§ Thickness § Deformation § Stresses § Reorientation of
fibers
PAM-FORM for TRIMS
CIDAUT (SP) COLBOND (NL) ENSAM (F) FAURECIA (F) GRUPO ANTOLIN (SP) GRUPO COPO (SP) HAYASHI TELEMPU (J) KOTOBUKIYA FRONTE (J) MECAPLAST(F) MITSUIYA INDUSTRIAL (J) STANKIEWICZ (D) TOKYONOKO U. (J)
IMI
Composite Forming Example from Airbus UK (1/4) § Wing Box Forming
Rib
Airbus UK
Composite Forming Example from Airbus UK(2/4)
§ Forming Press
Airbus UK
PAM-FORM for
PLASTIC SHEET FORMING
Dr Patrick de Luca Product Manager
OUTLINE
§ PAM-FORM Overview
§ Composites Forming § Trims Forming § Plastic Sheet Forming § PAM-FORM for Plastic Sheet Forming Simulation § Examples of Applications to Demonstrate the benefit of using
TANK (Forming Processes)