Non Conventional Metalforming Process...
Transcript of Non Conventional Metalforming Process...
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Non Conventional Metalforming Non Conventional Metalforming Process AutomationProcess Automation
T. Primo, A. Anglani and A. EliaUniversity of Salento, Department of Engineering Innovation, Lecce
Technology and Manufacturing System Group
A. CarusoAgustaWestland S.p.A., Brindisi
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PMGr tabPMGr tabPMGr PanelPMGr PanelMFM Toolbar containing:MFM Toolbar containing:
Forming Strategy TreeForming Strategy TreeContextual Button BoxContextual Button Box
MFM GUI componentsMFM GUI components
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AGUSTA MFM GOALAGUSTA MFM GOALAgusta Metal Forming Manager (Agusta MFM) is an application intended to guide CAE analysts to design, manage and review forming processes for all products made by AgustaWestland, by modeling each production technology.
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MFM main featuresMFM main featuresMFM application guides users to:
Analyze a component starting from its CAD in order to verify forming feasibility (One Step Analysis) and to obtain the blank shape;Build a multi‐stage forming strategy, by defining a forming technique for each stage (Sigle Action Draw, Double Action Draw, etc)Assign to each stage a shape from which to create die tools Setup stage problemsRun and post stage problemsCreate stage reports
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ADM integrationADM integration
The main aim is to upload the entire project folder and data into ADM by mapping forming strategy project files with ADM entities.
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HF
MFM
PMGrADMSERVER
EngineeringIntelligence
Shared AreaPDMSERVER
Ls‐Dyna
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HF
MFM
PMGrADMSERVER
EngineeringIntelligence
Shared AreaPDMSERVER
Ls‐Dyna
Define and studyDefine and studyForming StrategyForming Strategy
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HF
MFM
PMGrADMSERVER
EngineeringIntelligence
Shared AreaPDMSERVER
Ls‐Dyna
Load/Save Forming StrategiesLoad/Save Forming StrategiesCreate/import Product CADCreate/import Product CADCreate/import initial blank CADCreate/import initial blank CADPerform inverse analysisPerform inverse analysisDefine stages sequencesDefine stages sequences
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HF
MFM
PMGrADMSERVER
EngineeringIntelligence
Shared AreaPDMSERVER
Products Products CADCAD
Ls‐Dyna
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HF
MFM
PMGrADMSERVER
EngineeringIntelligence
Shared AreaPDMSERVER Save/Load Save/Load
Forming StrategiesForming Strategies
Ls‐Dyna
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HF
MFM
PMGrADMSERVER
EngineeringIntelligence
Shared AreaPDMSERVER
Ls‐Dyna
Forming Tools CreationForming Tools CreationProblems setupProblems setupSimulations submissionSimulations submissionPostprocessingPostprocessingReportingReporting
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HF
MFM
PMGrADMSERVER
EngineeringIntelligence
Shared AreaPDMSERVER
Ls‐Dyna
Computing Computing stages simulationsstages simulations
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HF
MFM
PMGrADMSERVER
EngineeringIntelligence
Shared AreaPDMSERVER
Ls‐Dyna
Query strategiesQuery strategiesPerformance Performance
analysisanalysis
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Multistage Forming StrategyMultistage Forming StrategyProcess designers should answer to the following questions:
– How many stages the forming strategy is made by?
– Which type of operation is performed in each stage?
– What is the product shape of each stage?
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How many stages ?How many stages ?
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Strategy 2Strategy 2Strategy 1Strategy 1
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What is the product shape of each stage?What is the product shape of each stage?
Drawing tools will be created starting from the mesh of final product. Users will create the product of each forming stage by using HyperMorph. Then, by using HyperForm automations (i.e. Tool Build), the shapes of forming tools will be derived semi‐automatically (Punch, Die, Blank holders).
Morph shapes
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OP 30 Top Rib= final Product
What is the product shape of each stage?What is the product shape of each stage?
Morph shapes
OP20 Lateral Rib
OP10 Deep Drawing
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Forming StrategyForming Strategy
OP20OP20 Lateral Rib
OP10OP10 Deep Drawing
OP30OP30 Top Rib = Final Product
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Stage setup workflow Stage setup workflow
Stage made shape
Dynain from prev. StageOR INITIAL BLANK
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File system structureFile system structureLet’s suppose we have a forming strategy made of 2 forming operations named:
OP_10_DAD
OP_20_DAD
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Using HyperMorph to assign stage shapesUsing HyperMorph to assign stage shapes
Metamodel
OP_10_DAD OP_20_DAD
Assign each shape to a forming stage
Create morphing shapes from meta-model
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Setup Stage ProblemSetup Stage Problem
Stage shape (meta-model)
Stage tools
Problem setup
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Project Files StructureProject Files Structure
All project files are organized into a project directory.
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Project folderProject folder• Project folder contains:
– Pmgr instance file (.pmi)
– Blank.hf (hyperform file for blank model)
– Blank.dynain (initial blank in ls‐dyna format)
– Model.hf (hyperform file for meta‐model)
– Stages folders (in the example: OP_10_DAD, OP_20_DAD)
– OneStep folder (1Step)
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Stage FolderStage Folder• Stage model it is automatically saved at some key points, during editing:
metafile.hf tools.hf problem.hf
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Acknowledgements Acknowledgements
Authors are very grateful to “Regione Puglia” for funding this Project recognized as “Systems for development and optimization of the forming process of aeronautical components in aluminum alloys and innovative materials”. Special thanks go to AgustaWestland SpA and Parsec 3.26 srl which have the role of industrial partners of the Research Project.
Authors are very grateful to “Regione Puglia” for funding this Project recognized as “Systems for development and optimization of the forming process of aeronautical components in aluminum alloys and innovative materials”. Special thanks go to AgustaWestland SpA and Parsec 3.26 srl which have the role of industrial partners of the Research Project.