1、PDF外文：http:/ 中文 5520 字 出处： Journal of Engineering Design, 2004, 15(6): 551-561 附录 英文资料 Comparison of sheet-metal-forming simulation and try-out tools in the design of a forming tool A. ANDERSSON Today, sheet-metal-forming simulation is a poAwerful technique for predict
2、ing the formability of automotive parts. Compared with traditional methods such as the use of try-out tools, sheet-metal-forming simulation enables a significant increase in the number of tool designs that can be tested before hard tools are manufactured. Another advantage of sheet-metal-forming sim
3、ulation is the possibility to use it at an early stage of the design process, for example in the preliminary design phase.Today, the accuracy of the results in sheet-metal-forming simulation is high enough to replace the use of try-out tools to a great extent. At Volvo Car Corporation, Body Componen
4、ts, where this study has been carried out, sheet-metal-forming simulation is used as an integrated part in the process of tool design and tool production. 1 Introduction Traditionally, try-out tools are used to verify that a certain tool design will produce parts of the required quality. The try-out
5、 tools are often made of a cheaper material (e.g. kirksite) than production tools in order to reduce the try-out costs. This is a very time-consuming and cost-consuming method. However, today another more efficient technique is availablesheet-metal-forming simulation. This new technique is based on
6、the simulation of the forming process, and could result in a cost reduction of factor 10 and a time reduction of factor 15 for each hard tool. Sheet-metal-forming simulation technology is constantly developing and the results of the simulations are more and more accurate. In the future it will also
7、be possible to analyse more processes using sheet-metal-forming simulations. Today, the accuracy of the results in sheetmetal- forming simulation is high enough to replace the use of try-out tools to a great extent. 2 Method The purpose of this study is to analyse and compare the benefits and drawba
8、cks of the use of sheet-metal-forming simulation and try-out tools in the design of forming tools. The method employed in this study is based on the Production Reliability Matrix (PSM) (Rundqvist and Stahl 2001) together with a Process Correspondence Matrix (PCM) that has been developed especially f
9、or this study. The PSM is a matrix that categorizes the effects of different factors (parameters) in the process into different factor groups. The effect of each factor (parameter) is then assessed according to a scale of 03. Based on the results of the matrix, the parameters that have the most cons
10、iderable effects on the production process can be extracted, and a priority list for neutralizing or minimizing these effects can be made. The PCM has been developed through extensive interviews of senior experts in automotive component forming to analyse the correspondence between the results of sh
11、eet-metalforming simulations, the try-out tool and the quality of produced parts in actual production. 3Process for designing a forming tool Figure 1 shows a simplified flow of the production process of developing a forming tool at Volvo Car Corporation, Body Components (VCBC). The process of the de
12、sign of a forming tool includes a try-out phase where different designs of the tool are tested. This is a very important stage in the tool design process,in order to verify that the part will fulfil the required quality. It is very difficult to predict the result of a forming operation, but by using
13、 sheet-metal-forming simulation there is a possibility to gain valuable insight into the outcome of the forming operation. 3.1 Use of sheet-metal-forming simulation Sheet-metal-forming simulation can be used in several stages of a tool design process: early in the preliminary design phase, to enable
14、 rapid verification of different proposals for the design of automotive components to improve an existing process. Figure 1. Process for designing a forming tool at VCBC. 3.1.1. Requirements for sheet-metal-forming simulation. Sheet-metal-forming simulation requires the following: Simul
15、ation software. A computer-aided design (CAD) model of the part layout or a CAD model of the forming surfaces of the tool. Parameters for description of the specified sheet-metal material. Process parameters. Workstations (today the development of the personal computer (PC) is rapidly advancing so t
16、hat PCs will be a strong alternative in the future). A competent staff that can handle the software and analyse the results of the simulation. Simulation software. Today there is a variety of commercial software available on the market. In order to find suitable software, the area of use must be ana
17、lysed. The software package is different with regard to user-friendliness and flexibility. At VCBC, where this study was performed, two different software packages are used. One is Autoform (2001), which is user-friendly and provides fast results. This Preliminarydesign of part Part layout Hard forming tools/Process design Try-out tools Sheetmetal formingsimulation
