Sheet Metal Assembly Simulation with Approximate Forming Equilibrium
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Solution Overview
Problem
Existing methods for simulating and analyzing the assembly of sheet metal parts created by forming processes are computationally expensive, requiring repeated simulations that increase development time and resource usage.
Innovation Solution
A computer-implemented method that uses an approximate simulation to reduce computational load by determining strain and stress values based on reference geometry and material properties, allowing for efficient generation of an assembled part simulation model without the need for multiple forming simulations, and includes a scaling parameter to control material behavior and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If repeated FEM simulations are executed to simulate forming and assembly processes, then simulation accuracy and reliability are improved, but computational cost and development time increase
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing forming process results (including stress, strain, and geometry data) in a database before the assembly simulation. This allows the assembly simulation to directly utilize these pre-computed data without re-executing the forming simulations, significantly reducing computational time while maintaining simulation accuracy.
Solution Approach 2:
The patent creates a digital copy of the forming process results by generating a simulation model that replicates the forming outcomes (part geometry, material state, residual stresses) and stores it in a database. This copied data can be repeatedly used in assembly simulations without additional computational cost, resolving the contradiction between accuracy and time consumption.
2Manufacturing precision
If multiple forming simulations are performed to account for material behavior variations, then manufacturing precision is improved, but computational load increases
Solution Approach 1:
The patent implements parameter changes by introducing a scaling factor that modifies the elastic modulus in the assembly simulation based on forming process parameters (such as LDR - lateral draw ratio). This allows the simulation to account for material behavior variations without performing multiple separate forming simulations, reducing computational load while maintaining manufacturing precision.
Solution Approach 2:
The patent pre-calculates forming process parameters (LDR, strain distribution, stress state) and stores them in the database before assembly simulation. These pre-computed parameters are then used to adjust material properties in the assembly simulation, eliminating the need for repeated forming simulations and reducing computational energy consumption.
3Reliability
If detailed FEM models with full material properties are used for assembly simulation, then simulation reliability is improved, but device complexity increases
Solution Approach 1:
The patent segments the simulation process into two independent parts: (1) forming process simulation that generates detailed material state data, and (2) assembly simulation that utilizes this pre-computed data. By separating these processes and storing intermediate results in a database, the system maintains high reliability while reducing the complexity of the assembly simulation model itself.
Solution Approach 2:
The patent introduces an intermediary database that stores forming process results (geometry, stress, strain, material state) between the forming simulation and assembly simulation. This intermediary data structure allows the assembly simulation to access detailed material information without requiring the full complexity of the forming simulation model, thus reducing device complexity while maintaining reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly reduces computational costs and development time while maintaining suitable results for simulating the assembly process, enabling quick iterations and optimization of part design.
Implementation Method 1
for the material points of the FEM mesh, based on the associated strain values and on material properties of the blank, determining associated stress values; based on the FEM mesh with the associated stress values, determining displacements of mesh points that bring the mesh into an equilibrium state with regard to the stresses
Data Source
Figure 1~3
Figure 4~8
AI summary
A computer-implemented method serves for simulating and analysing an assembly of two or more formed sheet metal parts. It comprises simulating a forming process of each part by an approximate simulation (20), and then performing an assembly simulation (40). In order to allow for a quick iteration over different part geometries to assess the assembly, the approximate simulation (20) comprises • based on a reference geometry (10) of each part, estimating the deformation of a sheet metal blank required to attain the reference geometry (10); • based on this deformation, estimating stresses within the material of the formed part; • based on these stresses, estimating the shape of the formed part in which these stresses are in equilibrium, and using this shape as result (31) of the approximate simulation.