Sheet Metal Assembly Simulation Using Approximate Forming Equilibrium
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Solution Overview
Problem
Existing methods for simulating and analyzing the assembly of sheet metal parts formed through a forming process 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 generate a free part simulated geometry by determining strain and stress values based on a reference geometry, reducing the need for multiple forming simulations through an iterative process controlled by a scaling parameter, allowing for quick evaluation of variations and optimization of part design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If repeated FEM simulations are executed to simulate forming and assembly processes, then simulation accuracy and design assessment quality are improved, but computational cost and development time increase significantly
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 pre-computed data is then reused during assembly simulations, eliminating the need to repeatedly execute computationally expensive forming simulations while maintaining accuracy in assessing assembly-induced deformations
Solution Approach 2:
The patent creates simplified copies of the forming process results by storing essential data (mesh information, material properties, stress-strain states) in a database. These copies can be quickly retrieved and applied to assembly simulations without requiring the original complex forming simulations to be re-executed, thus reducing computational time while preserving simulation fidelity
2Manufacturing precision
If multiple forming simulations are performed to evaluate design variations, then design optimization quality is improved, but computational load and resource usage increase
Solution Approach 1:
The system pre-computes and stores forming process outcomes including geometry changes, stress distributions, and strain states in a database. When evaluating design variations, the assembly simulation directly utilizes these pre-computed results, allowing multiple design scenarios to be assessed with minimal additional computational effort beyond the initial forming simulation
Solution Approach 2:
The patent enables efficient evaluation of design variations by changing input parameters (such as material properties, forming conditions, or geometry) and reusing the established simulation framework. The database stores results that can be quickly queried with modified parameters, allowing design optimization without re-running complete forming simulations for each variation
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 approach significantly reduces computational load and development time while maintaining suitable results for simulating the assembly process, enabling efficient design and manufacturing of sheet metal parts and tools.
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
Implementation Method 2
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
Implementation Method 3
for the material points of the FEM mesh, based on the reference geometry, determining associated strain values from a geometric transformation required to bring a flat sheet of material into the shape according to the reference geometry
Data Source
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) comprisesbased 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.