Automated Scrap Trimming Simulation in Sheet Metal Forming
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Solution Overview
Problem
Current methods for simulating scrap trimming operations in sheet metal forming are cumbersome, error-prone, and require manual expertise, leading to inefficiencies and productivity losses due to stuck scraps and inappropriate die designs.
Innovation Solution
A time-marching simulation system using finite element analysis (FEA) models with cutting-edge nodes and trim vectors to establish trim lines, split finite elements, and conduct numerical simulations, separating trimmed and scrap portions with rigid and deformable elements, respectively, to accurately model and optimize scrap trimming operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual methods are used to create separate computerized models for each scrap portion, then the simulation can be conducted, but the process becomes cumbersome and error-prone requiring a priori expertise
Solution Approach 1:
The system automatically generates computerized models for scrap portions using the FEA model and trim line information without requiring manual intervention. The application module autonomously creates node-pairs, defines element sets, and sets up contact pairs, eliminating the need for user expertise in manual modeling while maintaining simulation accuracy.
Solution Approach 2:
The system performs preliminary actions by automatically creating all necessary computerized models, element sets, and contact definitions before the actual trimming simulation. This pre-processing automation eliminates the need for manual model creation and ensures all components are properly configured before analysis begins.
2Productivity
If inappropriate die structure design is used, then the initial setup is simpler, but scraps get stuck and do not separate from trim edges causing shutdowns
Solution Approach 1:
The system performs preliminary analysis by simulating the trimming operation and scrap separation behavior before actual production. This allows identification of potential sticking problems and die structure deficiencies before they cause shutdowns, enabling proactive design optimization.
Solution Approach 2:
The simulation provides feedback on scrap behavior and potential sticking issues. This information is used to optimize die structure design, ensuring that scrap portions will properly separate from trim edges during actual operation, thereby maintaining high productivity without shutdowns.
3Adaptability or versatility
If complex trimming operations are performed, then more scrap portions can be removed, but the likelihood of scraps getting stuck increases
Solution Approach 1:
The system performs preliminary simulation of complex trimming operations to predict scrap behavior and identify potential sticking problems before actual production. This allows optimization of trim steel geometry, trim post placement, and scrap chute design to prevent sticking even in complex multi-trim scenarios.
Solution Approach 2:
The simulation acts as an intermediary between design and production, allowing virtual testing of complex trimming operations. By analyzing scrap trajectories and contact forces in the simulation, designers can optimize die structures to handle complex trimming without the harmful sticking effect that would occur in actual production.
Data Source
AI summary
Physical tools for trimming operations in forming of a sheet-metal part are set up based on numerically-simulated structural behaviors. FEA model representing a stamped sheet metal before trimming and a trimming operation setup are received. Each trim-steel contains a set of cutting-edge nodes associated with trim vector. At least one trim line is established by projecting cutting-edge nodes onto the FEA model according to the trim vector. Numerically-constrained node-pairs along the trim line are created at intersections with edges of crossed finite elements. FEA model is modified by splitting the crossed finite elements to preserve original geometry and to ensure numerical stability. New finite elements are defined using one of the nodes in corresponding node-pairs such that no finite element straddles the trim line. At each solution cycle of a time-marching simulation of trimming operations, simulated structural behaviors are obtained as the scrap portion(s) deforms and falls accordingly.