Ford Global Technolgoies, LLC

Ford Motor Company Limited

Yinong Shen

Evangelos Liasi

Feng Ren

S George Luckey, Jr

Zhiyong Cedric Xia

Liang Huang

Yuan Gan

Jing Wu

Joon Kang

Rob Vaughn Degenhardt

A method of manufacturing a panel using an initial die and a series of secondary dies includes sequentially defining multi-dimensional models for the series of secondary dies. The method includes simulating a geometry of an npre-panel, defining a multi-dimensional model of the nsecondary die based on the simulated geometry of the npre-panel, simulating operation of the nsecondary die on the npre-panel to determine geometry of an (n+1)pre-panel, and determining a deviation between the simulated (n+1)pre-panel and a target pre-panel geometry. If the deviation is outside tolerance, the method includes iteratively: adjusting the multi-dimensional model of the nsecondary die, simulating operation thereof to determine an adjusted simulated geometry of the (n+1)pre-panel, and determining a deviation between the adjusted simulated geometry of the (n+1)pre-panel and the target (n+1)pre-panel, until the deviation is within the tolerance limit.

Method of manufacturing a vehicle panel to reduce deviation between pre-panels and subsequent secondary forming dies

A method of evaluating a sheet metal stamping simulation is provided. The method may include defining elements of a finite-element mesh representing a stamped panel, operating on the elements to simulate deformation of the panel during stamping to generate, for each of the elements, incremental differential major and minor plastic strain values, applying a weighting factor to temporally adjacent pairs of the values to generate smoothed values, deriving, from the smoothed values and for each of the elements, a plurality of plastic strain incremental ratios representing plastic flow direction of the elements during the deformation, and altering colors of a map based on the ratios to represent changes in severity of plastic deformation of the stamped panel.

Method for predicting plastic strain ratio from stamping simulation

A single action draw press and a draw die set for the single action draw are disclosed. The single action draw press and die include a bolster and a stationary punch. A cushion is assembled to the bolster to support a binder ring that is adapted to be engaged by a die attached to a press ram. The die is reciprocated by the press ram relative to the bolster while a mechanical lock engages the die and the binder ring. The die contacts the binder ring and a mechanical lock secures the die and binder ring together while the die draws a panel over the stationary punch.

Draw die and binder lock

The stamping of a metal sheet within a stamping die is simulated. The die includes a drawbead running perpendicular to a draw direction. A plurality of successive states are generated for iteratively representing the metal sheet from a blank shape to a final stamped shape. The drawbead is represented as a two-dimensional flat band within a model of the stamping die. Forces acting on the metal sheet are calculated at each successive state to define a next successive state. The calculating step includes a restraining force of the drawbead acting on the metal sheet calculated in response to a predetermined function of a length of the metal sheet engaged in the flat band in respective states. The particular width and location of the flat band achieve improved accuracy of estimating the restraining force.

Pseudo-physical modeling of drawbead in stamping simulations

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Canton, MI, United States of America

Yinong Shen