Simulation of sheet metal forming with FORGE®

FORGE_sheet-metal_forming_pillar_final_shape

Sheet metal forming is used for manufacturing thin products. The process can be carried out as a cold or a hot forming process (Hot Press Forming, HPF). 

FORGE® simulates both types of sheet metal forming operations in order to optimize process parameters and to ensure the parts’ quality.

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predictive simulation

FORGE® allows accurate prediction of:

  • Final shape with the prediction of final thickness
  • Defects like striction
  • Residual stresses
  • Press loads including loads to apply on the blank holders
  • Metallurgic changes in the case of Hot Press Forming

FORGE_sheet_metal_FlowLimitDiagramFlow limit diagram with FORGE®

 

features oF FORGE® for sheet metal forming

  • Dedicated meshing technology for thin products allowing multiple elements in the thickness without impacting CPU time

FORGE_sheet_metal_forming_cooling_channels

  • Genuine elasto-plastic model for cold operations for accurate elastic spring back and residual stresses
  • Anisotropic models and complex hardening models (kinematic hardening)
  • For HPF, embedded heat treatment models to accurately predict metallurgic phase transformation and martensite production
  • Accurate temperature prediction thanks to coupled part-dies analysis
  • With a unique software, multiple operations can be achieved: forming operations as well as subsequent blanking operations are accurately and easily analyzed

 

Case study: sheet metal forming of a car B-pillar

FORGE_emboutissage (2)

The example presented here corresponds to the hot forming of a B-pillar in a car body. Following the stamping operation, the part formed is cooled between the two dies which makes it possible to check its microstructure and its final shape. The FORGE® software can be used in this type of configuration and considering the microstructural changes.

FORGE-emboutissage

SMF_Thickness

Thickness evolution

SMF_Temperature

Temperature evolution

 

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