Altair India

HYPERWORKS FOR STUDENTS

Projects using HyperForm and Radioss

Optimization of Blankholding Force for a Seat Riser





Areas covered:

Data import and geometry cleanup.

Layout and organization of components of the press-tool.

Specification of process parameters.

Impact of drawbeads and blankholding force on wrinkles.

Description of the Problem: A die manufacturer has been asked to design and manufacture the die for a car seat riser - a sheet metal component that has a nominal thickness = 0.7mm and is made of CRDQ. Since the geometry is complex, the CAD data has been supplied to the die designer, who has to design, manufacture, verify and supply the die to the component manufacturer. The die designer has created the die-face, using the CAD model of the component as the base. The problem now is to freeze several process parameters. The first information that the component manufacturer needs is the size of press that will be needed. That is, the press tonnage must be confirmed. The die designer also wants to know if any draw beads will be required, so that the manufacturing process can be planned while the design activity proceeds. The component specifications call for the thickness to be within 10% of the nominal thickness.

Multi-stage Forming of a Suspension Cover





Areas covered:

Data import and geometry cleanup.

Layout and organization of components of the press-tool.

Specification of process parameters.

Die design for multi-stage forming.

Description of the Problem: The die design for a cover used in the suspension of a truck has been supplied. The component is 2 mm thick, and the designers want to form the component in a single stage. This is a little ambitious, since the previous tool for a similar component used two stages. Given the advantages that a reduction-in-stages has, the die designers want to know whether the current design will work. The component is made of CRDQ (Cold Rolled Die Quality steel), and is permitted a 15% variation in thickness over the nominal thickness (2 mm). The product data has been supplied, based on which the press-shop has arrived at a preliminary die design. The die designer has created the die-face, using the CAD model of the component as the base. There are two problems the designers want to address. The first is to estimate several process parameters. Principally, the analysis must indicate whether or not draw beads will be required, and whether a lubricant must be used or not. Then, depending on whether two stages are needed or one is adequate, the size of press that will be needed must be estimated. That is, the press tonnage must be calculated.

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