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The blueprint

Sheet metal part transfer process in high-volume transfer press is a critical phase of stamping manufacturing operations

Understanding the dynamic behaviour of sheet metal during transfer from die station to station is an urgent task in tooling design phase to achieve optimum transfer motion design, avoiding high cost equipment damage and improving production uptime.

A ltair’s newly developed HyperDieDynamics (HDD) is a tool that analyses sheet metal transfer dynamic behaviour through its intuitive graphic user interface (GUI) and engineering intelligence.

Simone Bonino Manager, Altair USA,simone@altair.com
HDD Browser Tree

By introducing flexible body property and virtual model of the stamping press line, users can easily conduct a panel transfer dynamic analysis with MotionSolve, visualising the in-motion blank deflections, accelerations, and resultant forces. It is a useful analytical tool to improve automation tooling design and transfer motion operational parameters. The process includes a reduced model representing one press station created and several types of real parts simulated in order to validate the virtual press model and improve the robustness of the solution. The simulation models generated to achieve very accurate results have been complex as a new user would require significant training in using HyperWorks. To simplify the usage a customised GUI has been created, reducing the pre-processing time from several hours to a few minutes. The results have been finally validated correlating the animations with a set of hi-res videos acquired during the real stamping operations in the production plant. Altair Engineering developed an innovative methodology to simulate the dynamics and kinematics of tri-axis transfer and crossbar presses, as well as other types of special stamping press lines. Based on long-term Altair’s sheet-metal forming die design knowledge and on Altair multi-body dynamics solver (Altair MotionSolve), Altair HyperDieDynamics is a process simulation environment. Based on physical behaviour, it predicts motions and forces within complex multi-body systems like sheet metal forming transfer dies. Altair’s HDD offers a unique set of process simulation capabilities, including:

Panel deflection analysis

The easy-to-use HDD framework allows users to quickly create a flexible and dynamic model of the transfer layout. With simple inputs, users can dynamically analyse and optimise the behaviour of the part through the transfer line. The powerful post-processing templates provide in-motion visualisation and analysis of deflection, acceleration and resultant forces, either on the blank or on the panel.

The virtual dies environment

HDD provides massive advantages by simulating and analysing an entire die-set process & verifies the imbalance of press bolsters by generating a 3D, dynamic process layout. It reduces casting-model and die-making errors by validating each main die component early in the process engineering phase. It highlights potential bouncing due to stroke velocity, with the ability to program the optimal motion curves and predict the maximum target production rate.

It helps obtain early feedback on possible stamping operation failures, to virtually set up the entire lines and fine tune the die sets production at the desired strokes per minute (SPM). Its unique characteristic is to transform a static die design into a dynamic press simulation environment. It helps in identifying and controlling different kinds of dies and press lines problems such as:

Virtual die and line assembly validationIn-motion blanks and panels deflection analysis (panel vibration simulation)Dynamic collision and proximity checkOptimising SPMScrap-falling prediction capabilitiesWear sensitivity

Hi-speed transfer presses

The new generation of crossbar transfer presses is based on modular transfer systems, which provides flexible part transferring systems between die stations (figure1).At the heart of this new generation of crossbar transfer presses is a modular transfer system, which guarantees the safe transport of parts between the various forming stations. In contrast to conventional mechanical or electrical transfer systems using a central drive system, the new modular transfer system consists of autonomous units equipped with their own electronic drives. Independent drives mean that press speed and transfer motion can be adjusted individually, so that even difficult shapes with inclined forming positions in the die can be produced in continuous operation. The machine is also much more flexible than conventional transfer presses and can produce a wider range of parts.

Although kinetic simulation has been used in stamping engineering and manufacturing system for few years now, it doesn’t answer the requests of a more advanced analysis of the new hi-speed transfer presses behaviour. As a result, flex body dynamic analytical tools are required for advanced simulation.

To conclude

HDD is an effective new tool to conduct flex body dynamic analysis to:

Demonstrate panel transfer behaviour (displacement, acceleration, stress, etc.)Optimise tooling design, such as cup layout & optimise motion parameters, minimise dynamic impact while achieving optimum production speed

The MBD approach (MotionView/MotionSolve) grants a reasonable run time (few minutes to run an even complex part). Hence, a sensitivity analysis running stochastic studies (Altair HyperStudy) linked to the multibody dynamics simulation can be eventually done easily, generating a quality indicator of the transfer process robustness.

• more@click-Code: ADI02026

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