WO2016017775A1 - モデル設定方法、成形シミュレーション方法、成形用工具の製造方法、プログラム、プログラムを記録したコンピュータ読み取り可能な記録媒体および有限要素モデル - Google Patents
モデル設定方法、成形シミュレーション方法、成形用工具の製造方法、プログラム、プログラムを記録したコンピュータ読み取り可能な記録媒体および有限要素モデル Download PDFInfo
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- WO2016017775A1 WO2016017775A1 PCT/JP2015/071703 JP2015071703W WO2016017775A1 WO 2016017775 A1 WO2016017775 A1 WO 2016017775A1 JP 2015071703 W JP2015071703 W JP 2015071703W WO 2016017775 A1 WO2016017775 A1 WO 2016017775A1
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- forming tool
- surface layer
- metal plate
- forming
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/20—Making tools by operations not covered by a single other subclass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D53/00—Making other particular articles
- B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2113/00—Details relating to the application field
- G06F2113/24—Sheet material
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/18—Manufacturability analysis or optimisation for manufacturability
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Definitions
- the present invention relates to a model setting method of a finite element model used for a metal plate forming simulation by a finite element method, a forming simulation method using a set finite element model, a forming tool manufacturing method using the same, a program, and a program
- the present invention relates to a computer-readable recording medium and a finite element model.
- the analysis target is often modeled with a shell element for calculation.
- the analysis model is simplified by imparting the characteristics of a rigid body to the forming tool and the characteristics of a deformed body (elastic-plastic body) to the metal plate.
- the forming tool is also a deformed body (elastoplastic), and in the actual forming of the metal plate, the forming proceeds with the elastic deformation (in some cases, plastic deformation) of the forming tool.
- the analysis model as described above has a problem that the consistency between the analysis result of the molding simulation and the actual measurement value of the actual molded product is lowered.
- the use of high-strength materials to reduce the weight of parts and improve the collision function is actively performed, and the molding load increases when molding a high-strength metal plate. The influence of elastic deformation of the forming tool in can not be ignored.
- the forming tool is an elasto-plastic material, so in fact not only the thickened part of the metal plate but also the thickened part.
- the forming tool also contacts other parts.
- the forming tool is modeled on the assumption that it is a rigid body, the forming tool comes into contact with only the thickened portion of the metal plate. Therefore, in order to improve the accuracy of the forming simulation, it is desired to consider the elastic deformation of the forming tool.
- an analysis model in which a forming tool is modeled by a solid element and an elastic body or an elastic-plastic body is given can be considered.
- the creation of an analysis model (mesh division) and the execution of analysis are much more laborious. Time is needed. For this reason, it is not realistic to use such an analysis model in a mass production site where many parts are developed.
- Patent Document 1 and Patent Document 2 the mold is assumed to be a rigid body, only the mold surface is modeled as a shell element, a plate forming simulation is performed, and the mold is assumed to be an elastic body and is modeled as a solid element. Input the nodal reaction force obtained from the above plate forming simulation, perform mold rigidity simulation, reflect the mold deflection distribution obtained by the above mold rigidity simulation, and perform the above plate forming simulation again. It is disclosed.
- the present invention has been made in view of the above problems, and an object of the present invention is to set a model of a finite element model so that a metal plate forming simulation can be executed with high accuracy and efficiency.
- the object is to provide a method, a forming simulation method, a forming tool manufacturing method, a program, a computer-readable recording medium storing the program, and a finite element model.
- the inventor In order to grasp how the forming tool is elastically deformed during the formation of the metal plate, the inventor modeled the forming tool with a shell element to give the characteristics of a rigid body, and the forming tool with a solid element. A metal plate forming simulation by the finite element method was performed for comparison with the modeled and elastic or elasto-plastic characteristics. As a result, when imparting elastic or elasto-plastic properties to a finite element model of a forming tool, it is not necessary to target the entire forming tool, only the vicinity of the surface in contact with the metal plate of the forming tool. I found out that it should be the target.
- the forming tool was modeled as a virtual two-layer structure consisting of a surface layer in contact with the metal plate and a substrate supporting the surface layer, and the characteristics of the elastic or elasto-plastic material on the surface layer. It is found that by imparting a rigid body characteristic to the substrate, it is possible to control the rigid body displacement while considering the elastic deformation of the molding tool surface and maintaining the overall shape of the molding tool. It came to complete.
- the present invention is a model setting method in which a finite element model for simulating the forming of a metal plate by a forming tool using a finite element method is set by a processor provided in the computer.
- a finite element model for simulating the forming of a metal plate by a forming tool using a finite element method is set by a processor provided in the computer.
- the setting of the forming tool model to be represented at least a part of the metal plate contact surface that contacts the metal plate is set as a surface layer having characteristics of an elastic body or an elasto-plastic body in the forming tool model.
- a model setting method for setting a portion of the tool model for supporting the surface layer to a base body having a rigid characteristic is provided in which a finite element model for simulating the forming of a metal plate by a forming tool using a finite element method.
- the surface layer is set to a shell element, a thick shell element, or a solid element.
- the base is set to a shell element, a thick shell element, or a solid element.
- the forming tool model expressed by the surface layer and the base is a model of the region in the vicinity of the surface of the forming tool along the metal plate contact surface.
- the thickness of the surface layer is set to 0.2 to 5.0 times the thickness of the base metal of the metal plate. Further, the thickness of the surface layer may be set to 1.0 to 10 mm.
- the “surface layer thickness” refers to the virtual thickness of the shell element, or the thickness of the thick shell element or solid element.
- the base material thickness here is the thickness of the metal plate before being formed by the forming tool.
- a portion where the load concentrates on the forming tool at the time of forming the metal plate may be set as the surface layer.
- At least one of the forming tool models may be represented by a finite element model having a surface layer and a substrate.
- a forming simulation method for simulating forming of a metal plate by a forming tool using a finite element method wherein a metal plate model setting step for setting a metal plate model representing the metal plate, and the forming tool A forming tool model setting step for setting a forming tool model to be represented, and an analysis step for simulating the forming of the metal plate by the forming tool using the metal plate model and the forming tool model.
- the forming tool model setting step includes a forming simulation method including a first setting step of setting a first forming tool model using the model setting method described above.
- the forming tool model setting step includes a second setting step of setting a second forming tool model in which the forming tool is represented by a rigid shell element, and includes the metal plate model and the second forming tool model.
- the second forming tool model needs to be changed based on the thickening amount and the forming load of the metal plate obtained by the first forming simulation. If it is determined that the second forming tool model needs to be changed, a second forming simulation for analyzing using the first forming tool model may be performed.
- the present invention also provides a method for manufacturing a forming tool, characterized by designing and manufacturing a forming tool using the above-described forming simulation method.
- the model setting among the forming tool models, at least a part of the metal plate contact surface that contacts the metal plate is set to a surface layer having the characteristics of an elastic body or an elastic-plastic body, and Among them, a program is provided for setting a portion supporting the surface layer as a base having a rigid characteristic.
- a computer-readable recording medium recording a program for causing a computer to execute a process of setting a finite element model for simulating the forming of a metal plate by a forming tool using a finite element method,
- the setting of the forming tool model representing the forming tool at least a part of the metal plate contact surface in contact with the metal plate in the forming tool model is set to the surface layer having the characteristics of an elastic body or an elastic-plastic body.
- molding is provided.
- a finite element model of the forming tool used for the simulation of forming the metal plate by the forming tool, wherein at least a part of the surface layer of the metal plate contact surface of the forming tool is an elastic body or an elastic-plastic body.
- a finite element model is provided in which the substrate that is represented and that supports the surface layer is represented by a rigid body.
- the finite element model of the forming tool expressed by the surface layer and the base is a model of the region in the vicinity of the surface of the forming tool along the metal plate contact surface.
- the surface layer expressed by an elastic body or an elasto-plastic body may be a shell element, a thick shell element, or a solid element.
- the base body expressed as a rigid body may be a shell element, a thick shell element, or a solid element.
- At least a part of the blank holder of the molding tool may be included in at least a part of the surface layer. Further, at least a part of the surface layer may include a convex portion of the molding tool. Furthermore, in the finite element model of the molding tool for molding a molded product having a curved surface from the metal plate, at least a part of the surface layer includes the molding tool corresponding to the curved surface of the molded product. An area may be included.
- the thickness of the surface layer may be set to 1.0 to 10 mm.
- the “surface layer thickness” here also refers to the virtual thickness of the shell element, or the thickness of the thick shell element or solid element.
- FIG. 5 is a schematic diagram showing a finite element model of a forming tool used in a forming simulation method according to an embodiment of the present invention, where the surface layer is an elastic body or an elastic-plastic shell element, and the base is a rigid shell element. Show.
- FIG. 4A It is the schematic diagram which modeled a part of FIG. 4A. It is a schematic diagram showing a finite element model of a forming tool used in a forming simulation method according to an embodiment of the present invention, the surface layer is an elastic body or an elastic-plastic thick shell element, or an elastic body or an elastic-plastic body The case where the solid element and the base body are rigid shell elements is shown. It is the schematic diagram which modeled a part of FIG. 5A.
- FIG. 5 is a schematic diagram showing a finite element model of a forming tool used in a forming simulation method according to an embodiment of the present invention, where the surface layer is an elastic or elastic-plastic solid element, and the base is a rigid solid element Indicates. It is the schematic diagram which modeled a part of FIG.
- FIG. 6 is a schematic perspective view showing a finite element model of the forming tool of Comparative Example 1.
- FIG. 10 is a schematic perspective view showing a finite element model of a forming tool of Comparative Example 2.
- FIG. 10 is a contour diagram showing strain distribution in the height direction (Z direction) of a forming tool in a forming simulation of Comparative Example 2.
- FIG. 3 is a schematic perspective view showing a finite element model of the forming tool of Example 1.
- FIG. It is a schematic perspective view which shows the finite element model of the shaping
- FIG. It is a schematic perspective view which shows the finite element model of the shaping
- FIG. 10 is a schematic perspective view showing a finite element model of a forming tool of Example 5.
- FIG. FIG. 6 is a contour diagram showing a surface pressure distribution of a blank holder in molding simulations of Comparative Examples 1 and 2 and Examples 1 to 3.
- FIG. 6 is a plan view showing a cross-sectional position of a molded product in molding simulations of Comparative Examples 1 and 2 and Examples 1 to 3. It is sectional drawing in the II cutting
- the model setting method and the molding simulation method described below can be provided as a program executable by a computer for executing each process.
- a CPU Central Processing Unit
- ROM Read Only It
- RAM memory
- RAM random access memory
- the recording medium can be, for example, a magnetic disk, an optical disk, a magneto-optical disk, a flash memory, or the like.
- the above program may be distributed via a network, for example, without using a recording medium.
- a model setting method is a method of setting a finite element model for simulating the forming of a metal plate by a forming tool using a finite element method by a processor provided in a computer.
- a model setting method in the setting of the forming tool model representing the forming tool, at least a part of the metal plate contact surface that comes into contact with the metal plate model representing the metal plate among the forming tool models is an elastic body or A surface layer having an elastic-plastic characteristic is set, and a portion of the forming tool model that supports the surface layer is set to a base having a rigid characteristic.
- a metal sheet forming simulation is performed using the finite element model set by the model setting method.
- FIG. 1 is a schematic perspective view showing an example of a molded product obtained by molding a metal plate.
- a molded product 30 shown in FIG. 1 is a hat member obtained by press-molding a metal plate.
- a molded product 30 (hat member) shown in FIG. 1 is obtained by molding a metal plate using, for example, a molding tool shown in FIG.
- FIG. 2 is a cross-sectional view showing an example of a forming tool.
- a molding tool 10 ⁇ / b> A shown in FIG. 2 is a press molding die, and includes a die 2, a punch 3, and a blank holder 4.
- a molded product 30 (hat member) shown in FIG. 1 uses, for example, a molding tool 10A shown in FIG. 2 to hold the metal plate 1 with the die 2 and the blank holder 4, and to the gripped metal plate 1 It is obtained by pressing the punch 3.
- the forming simulation method according to the present embodiment is a method for simulating the forming of a metal plate using a forming tool as shown in FIG. 2, and the simulation result is used for designing the forming tool and the like. It is possible.
- a model representing the forming tool is set by the model setting method according to the present embodiment.
- FIG. 3 is an example of a forming tool model set by the model setting method according to the present embodiment, and is a schematic cross-sectional view showing the forming tool model shown in FIG.
- each of the die model 12, the punch model 13, and the blank holder model 14 is modeled by a virtual two-layer structure of a surface layer and a substrate.
- the die model 12 includes a surface layer 12a that contacts the metal plate model 11 and a base body 12b that supports the surface layer 12a.
- the punch model 13 includes a surface layer 13a that contacts the metal plate model 11 and a base body 13b that supports the surface layer 13a.
- the blank holder model 14 has a surface layer 14a that contacts the metal plate model 11 and a base body 14b that supports the surface layer 14a.
- the surface layers 12a, 13a, and 14a have elastic or elasto-plastic characteristics, and the base bodies 12b, 13b, and 14b have rigid characteristics.
- the bases 12b, 13b, and 14b have a thickness, but it is not necessary to have a thickness.
- FIG. 13 and FIG. 14 to be described later show one configuration example of the finite element model of the forming tool model shown in FIG.
- the surface layers 12a, 13a, and 14a are elastic or elastic-plastic shell elements
- the base bodies 12b, 13b, and 14b are rigid shell elements. It has become.
- the metal plate model 11 is modeled with shell elements.
- One forming tool is represented by the paired surface layer and substrate.
- a die is represented by a pair of surface layer 12a and base 12b.
- the base body 12b supports the surface layer 12a by setting a predetermined constraint condition between the surface layer 12a and the base body 12b.
- it expresses a rigid displacement integrally with the surface layer 12a.
- the constraint conditions are similarly set for the surface layer 13a and the base body 13b, and the surface layer 14a and the base body 14b.
- a rigid constraint condition may be set between the surface layer and the substrate, and each element is configured between the element representing the surface layer of the finite element model and the element representing the substrate. You may integrate by sharing at least some nodes.
- the surface layers 12a, 13a, and 14a are thick shell elements or solid elements of an elastic body or an elastic-plastic body, and the base bodies 12b, 13b, and 14b. Is modeled with a rigid shell element.
- the metal plate model 11 is modeled with shell elements.
- the constraint conditions are set between the surface layer 12a and the base body 12b, the surface layer 13a and the base body 13b, and the surface layer 14a and the base body 14b.
- the base 14b of the blank holder model 14 is not shown because it is hidden by the surface layer 14a.
- the forming tool is modeled by a virtual two-layer structure of a surface layer in contact with a metal plate and a substrate supporting the surface layer, and the surface layer has characteristics of an elastic body or an elastic-plastic body.
- the substrate a characteristic of a rigid body.
- the base body since the base body has the characteristics of a rigid body, it can usually be a shell element.
- the surface layer is set on at least a part of the metal plate contact surface in contact with the metal plate in the forming tool, and is set only in the region near the surface.
- a metal plate contact surface means the whole surface which contacts the metal plate model showing a metal plate among the tool models for shaping
- the region near the surface of the forming tool refers to a region from the surface of the forming tool to a predetermined thickness toward the inside of the tool. Therefore, even if the surface layer is modeled with solid elements, the time for creating the finite element model of the forming tool can be shortened as compared with the case where the entire forming tool is modeled with solid elements.
- the surface layer is given the characteristics of an elastic body or elasto-plastic body, but compared to the case where the entire forming tool is modeled as a solid element of an elastic body or elasto-plastic body, the molding simulation should be performed in a short time. Can do. Therefore, it is possible to perform a metal plate forming simulation with high accuracy and efficiency.
- Finite element model of forming tool In the finite element model of the forming tool according to the embodiment of the present invention, at least a part of the surface layer of the metal plate contact surface of the forming tool is represented by an elastic body or an elasto-plastic body, and the base body supporting the surface layer is a rigid body. It is a model that is expressed. A finite element model of one forming tool is formed by combining the surface layer and the substrate.
- the surface layer may be any of a shell element, a thick shell element, and a solid element, and among them, a shell element is preferable. This is because the creation time of the finite element model of the forming tool can be shortened. Further, when the surface layer is a solid element or a thick shell element, the number of divisions in the thickness direction is appropriately selected according to the thickness of the surface layer described later. The number of divisions in the thickness direction of the solid element or the thick shell element is preferably as small as possible, for example, about 1 to 2 divisions. This is because the creation time and analysis time of the finite element model of the forming tool can be shortened.
- the thickness of the surface layer is set.
- the thickness of the surface layer is appropriately set according to the material of the metal plate, the plate thickness, the size, the material of the forming tool, the forming load, and the like.
- the thickness of the surface layer may be determined in advance by modeling a molding tool with a solid element of an elastic body or an elastic-plastic body and performing a molding simulation. Specifically, the molding tool is modeled with a solid element of an elastic body or elastic-plastic body, a molding simulation is performed, the strain distribution in the thickness direction near the surface of the molding tool is analyzed, and the thickness at which strain can occur May be set to the thickness of the surface layer.
- the general shell element is formulated assuming that the normal stress in the thickness direction is always zero, and the stress balance cannot be expressed.
- a shell element that can take into account the stress in the thickness direction has been proposed, and the use of this shell element can improve the analysis accuracy for processing in which compressive deformation is imparted in the thickness direction. It is possible to use a shell element capable of considering the stress in the plate thickness direction even for the surface layer of the finite element model in the model setting method according to the present embodiment.
- the base is usually a shell element in order to shorten the creation time of the finite element model of the forming tool.
- the substrate may be, for example, a solid element or a thick shell element that is divided into one in the thickness direction.
- the finite element model of the forming tool expressed by setting the surface layer and the base as described above is a model of the region near the surface of the forming tool along the metal plate contact surface.
- the finite element model of the forming tool expressed by the surface layer and the substrate according to the present embodiment is not a model of the entire forming tool, but only the region near the surface of the forming tool, for example, as shown in FIG. Is modeled. This makes it easy to set up a finite element model and can set up a model with higher accuracy than the model represented by a conventional rigid shell element, so the metal plate forming simulation can be executed accurately and efficiently. It becomes possible to do.
- a virtual layer 15a has a virtual thickness.
- a shell element of t is disposed, and a shell element having a virtual thickness of zero is disposed as the base body 15b, for example, in contact with the surface layer 15a.
- the surface layer 15a which is a shell element shall be arrange
- the base body 15b has a virtual thickness of zero, but is represented by a thick line in FIG. 4A.
- one shell element is expressed as a surface formed by connecting, for example, four nodes.
- the virtual thickness of the base body 15b is zero here, the present invention is not limited to this, and a predetermined thickness can be set as the virtual thickness of the base body 15b.
- the nodes constituting the surface shell element and the nodes constituting the shell element of the base are defined in order to shorten the analysis model construction time and analysis time. They may be shared and integrated for modeling.
- the shell element representing the surface layer 15a is given elastic or elasto-plastic characteristics
- the shell element representing the base body 15b is given rigid characteristics.
- the molding according to the embodiment of the present invention is performed. It is possible to set a finite element model used for the simulation.
- the virtual surface in contact with the metal plate of the elastic or elastic-plastic shell element representing the surface layer 15a is deformed.
- the rigid shell element representing the base body 15b is not deformed other than the rigid body displacement. 4A and 4B, the region in the vicinity of the surface where the surface layer and the base are set is a region along the metal plate contact surface having a thickness t from the metal plate contact surface.
- a solid element having a thickness t as the surface layer 15a. Is arranged, and a shell element having a virtual thickness of zero is arranged in contact with the surface layer 15a as the base body 15b.
- the base body 15b has a virtual thickness of zero, but is represented by a thick line.
- one solid element is represented as a solid formed by connecting, for example, eight nodes.
- the surface layer 15a of the solid element may be divided into one in the thickness direction, or may be constructed by being divided into a plurality of portions in the thickness direction as shown in FIG. 5B.
- the time required for model construction and simulation increases as the number of divisions increases.
- the region in the vicinity of the surface where the surface layer and the substrate are set is a region along the metal plate contact surface having a thickness t from the metal plate contact surface.
- the thickness of the base body 15b is zero here, the present invention is not limited to this, and a predetermined thickness can be set as the thickness of the base body 15b.
- the surface layer is a solid element and the base body is a shell element
- the surface node of the solid element facing the base body and the shell of the base body are reduced. You may model by sharing the node of an element and integrating.
- the elastic element or elastic-plastic characteristic is imparted to the solid element representing the surface layer 15a, and the rigid characteristic is imparted to the shell element representing the base body 15b.
- the constraint condition between the surface layer and the substrate is satisfied by integrating the solid element of the surface layer and the shell element of the substrate.
- the surface layer of the solid element and the base body of the shell element are created as different models without node sharing, if a predetermined constraint condition such as a rigid body constraint is set between the surface layer 15a and the base body 15b, It is possible to set a finite element model used for the forming simulation according to the embodiment of the invention. The same applies to the case where the surface layer is a thick shell element.
- the surface layer 15a is represented by an elastic body or an elastic-plastic solid element
- the elastic body or the elastic-plastic solid element representing the surface layer 15a is deformed by receiving a load applied to the surface of the surface layer 15a.
- the rigid shell element representing the base body 15b is not deformed other than the rigid body displacement.
- a solid element having a thickness tb is arranged in contact with the surface layer 15a as the base body 15b.
- the surface layer 15a of the solid element may be divided into one in the thickness direction, or may be constructed by being divided into a plurality of pieces in the thickness direction as shown in FIG. 6B.
- the solid element base body 15b may be divided into a plurality of parts in the thickness direction, but one division is sufficient in order to impart the characteristics of a rigid body.
- the vicinity of the surface in contact with the metal plate of the forming tool is modeled with at least two divided solid elements in the thickness direction, and at least one divided solid element located on the metal plate contact surface side is used as a surface layer 15a to give the characteristics of an elastic body or an elasto-plastic body,
- the remaining solid element located on the side opposite to the plate contact surface side may be used as the base body 15b to impart rigid characteristics.
- the solid element functioning as the surface layer 15a and the solid element functioning as the base body 15b are configured as a continuous integral finite element model.
- the integrated finite element model is a continuous model formed integrally by sharing the opposing faces and nodes with respect to the solid elements of the opposing surface layer 15a and base 15b.
- the present invention It is possible to set the finite element model used for the forming simulation according to the embodiment. Even when the surface layer 15a is an elastic body or an elastic-plastic solid element and the base body 15b is represented by a rigid solid element, the elastic body or the elastic-plastic body representing the surface layer 15a is received by receiving a load applied to the surface of the surface layer 15a. The solid element of deforms. On the other hand, the rigid solid element representing the base body 15b is not deformed except for the rigid body displacement. 6A and 6B, the region in the vicinity of the surface where the surface layer and the base are set is a region along the metal plate contact surface having a thickness t + tb from the metal plate contact surface.
- the thickness t of the surface layer 15a is preferably about 0.2 to 5.0 times the base metal thickness of the metal plate. If the thickness t of the surface layer 15a is less than 0.2 times the base metal thickness of the metal plate, local deformation of the mold surface due to the thickened portion cannot be sufficiently considered in the analysis. On the other hand, when the thickness t of the surface layer 15a is thicker than 5.0 times the thickness of the base material of the metal plate, the surface layer and the base body are smoothly and continuously continued in the in-plane direction at the convex shape portion such as the ridge line R portion of the forming tool. It may be difficult to model as an element group, or the analysis time may increase as the number of elements increases.
- the base material thickness is the thickness of the metal plate before being formed by the forming tool.
- the thickness t of the surface layer 15a is set to 1.0 to 10 mm. As described above, if the thickness t of the surface layer 15a is set to be smaller than 1.0 mm, local deformation on the mold surface due to the thickened portion cannot be sufficiently considered in performing the analysis. Further, when the thickness t of the surface layer 15a is larger than 10 mm, it becomes difficult to model the surface layer and the base body as a smoothly continuous element group in the in-plane direction at the convex portion such as the ridge line R portion of the forming tool. In some cases, the analysis time becomes longer as the number of elements increases.
- the “thickness t of the surface layer 15a” indicates the virtual thickness t of the surface layer 15a when the surface layer 15a is a shell element.
- the finite element model of the forming tool used in the forming simulation according to the present embodiment only needs to have a surface layer on at least a part of the metal plate contact surface of the model.
- all the portions in contact with the metal plate model 11 of the forming tool model 10B may be the surface layers 12a, 13a, and 14a.
- some of the portions that contact the metal plate model 11 of the forming tool model 10B may be surface layers 12a, 13a, and 14a.
- a part of the portion of the forming tool that contacts the metal plate is modeled as a two-layer structure, as shown in FIG. 7A, it contacts the metal plate model 11 of the forming tool model 10B.
- local portions may be the surface layers 12a, 13a, and 14a.
- the forming tool includes a plurality of forming tools
- at least one forming tool among the plurality of forming tools is modeled by a two-layer structure of a surface layer and a substrate. May be.
- the punch model 13, and the blank holder model 14 only the die model 12 and the blank holder model 14 are modeled by a two-layer structure of the surface layers 12a and 14a and the base bodies 12b and 14b. Yes.
- the influence of elastic deformation of the die and the blank holder may be increased.
- the die model 12 and the blank holder model 14 have a two-layer structure of the surface layers 12a and 14a and the base bodies 12b and 14b.
- the die model 12 and the blank holder model 14 have a two-layer structure of the surface layers 12a and 14a and the base bodies 12b and 14b.
- at least one of the die model 12 and the blank holder model 14 has a two-layer structure. It is good.
- a molding tool that is a model having a two-layer structure composed of a surface layer and a base is, for example, a member What is necessary is just to select suitably according to a shape, base material thickness, base material strength, etc.
- a metal plate is press-formed using a forming tool, and the flanges 32 and 34, the top plate surface 36, and the flanges 32 and 34 and the top plate surface 36 are connected as shown in FIG. 8A or 8B.
- the hat members 30A and 30B including the side wall surfaces 33 and 35 are obtained. As shown in FIG.
- the top plate surface 36 of the hat member 30A has a saddle type having a flat surface 36a in the longitudinal direction (Y direction) and a curved surface 36b curved in a concave shape in the height direction (Z direction).
- Y direction longitudinal direction
- Z direction height direction
- a thickened portion is likely to occur on the curved surface 36b of the top plate surface 36 or the side wall surfaces 33b and 35b continuous to the curved surface 36b.
- the punch model 13 corresponding to the curved surface 36b recessed in the height direction of the hat member 30A and the side wall surfaces 33b and 35b continuous to the curved surface 36b, and the die model 12 A region corresponding to the curved surface 36b and the side wall surfaces 33b and 35b of the hat member 30A is set on the surface layers 12a and 13a, and a portion for supporting the surface layers 12a and 13a is set on the base bodies 12b and 13b.
- the die model 12 and the punch model 13 may be set.
- One of the die model 12 and the punch model 13 may be a finite element model having a two-layer structure represented by a surface layer and a substrate.
- the side wall surfaces 33 and 35 of the hat member 30B are curved in a concave shape in the longitudinal direction (Y direction) toward the flat surfaces 33a and 35a and the width direction (X direction).
- a thickened portion is likely to be generated on the curved surfaces 33b and 35b of the side wall surface 33 or the top plate surface 36b continuous with the curved surfaces 33b and 35b.
- the region corresponding to at least the curved surfaces 33b and 35b of the side wall surfaces 33 and 35 and the top plate surface 36b continuous with the curved surfaces 33b and 35b is set as a surface layer among the forming tools, and A finite element model of a forming tool having a two-layer structure may be set by setting a portion supporting the surface layer as a base.
- the type of forming tool is appropriately selected according to the forming method of the metal plate.
- the molding simulation method according to the present embodiment can be applied to press molding such as draw molding and bending molding, roll forming, and the like, and examples of the molding tool include a mold and a roll. .
- the configuration of the forming tool is the same as that of a general forming tool.
- this invention is suitable when the intensity
- a metal plate forming simulation by the finite element method is performed using the finite element model of the forming tool set by the model setting method.
- General-purpose finite element method analysis software is used for the molding simulation.
- the surface layer and the base that are paired together represent one forming tool, so the base supports the surface layer and is a rigid body that is integrated with the surface layer.
- the substrate and the surface layer are coupled by setting a constraint condition between the substrate and the surface layer so that the displacement is possible.
- Examples of the metal plate forming method include press forming such as drawing and bending, and roll forming.
- the present invention is suitable for press molding, particularly draw molding.
- draw forming the metal plate is formed with a die and a blank holder while applying wrinkle pressure, so the forming load and surface pressure are likely to increase, and the influence of elastic deformation of the forming tool during metal plate forming increases. .
- a molding simulation can be performed with high accuracy by using the molding simulation method according to the present embodiment.
- the metal plate forming simulation method according to the embodiment of the present invention can be applied to any shape, and is not particularly limited as a formed product to be subjected to forming simulation, but partially with the progress of forming. It is preferable to apply to a molded product in which the plate thickness increases or decreases.
- a molded article for example, in a molded article having a hat-shaped cross section, a hat member having a curved shape in the width direction or the height direction in the longitudinal direction can be mentioned.
- the flange 32 on the inner side of the curve becomes an elongated flange that undergoes tensile deformation in the longitudinal direction as the molding proceeds.
- the flange 34 on the outer side of the curve becomes a contracted flange that undergoes compressive deformation in the longitudinal direction.
- the plate thickness is reduced, and in the contraction flange, the plate thickness is increased.
- the finite element model of the forming tool used in the forming simulation method according to the present embodiment is in contact with a metal plate, has a surface layer having characteristics of an elastic body or an elastic-plastic body, supports the surface layer, and is a rigid body. And a substrate having the following characteristics. Thereby, the shaping
- the finite element model used in the forming simulation is preferably an optimal model in consideration of the accuracy required for the forming simulation result, the creation time of the finite element model of the forming tool, the calculation time, and the like.
- the simulation result when the forming tool is modeled with a rigid shell element, if the accuracy of the simulation result is within an allowable range, the simulation result can be obtained in a short time, so that the model may be used. However, even if the calculation time is short, if the accuracy of the simulation results when using a finite element model in which the forming tool is constructed with a rigid shell element is out of the allowable range, a finite element model can be analyzed with higher accuracy. Need to build. Therefore, for example, as described below, it may be automatically determined which finite element model of a forming tool is used.
- Fig. 9 shows an example of automatic construction processing of a finite element model.
- a forming tool is modeled by a rigid shell element, and a forming simulation is performed (S100: first forming simulation).
- the finite element model of the forming tool used in step S100 is conventionally used, is easy to construct, and can reduce the calculation load of simulation.
- elastic deformation (or plastic deformation) of the forming tool occurs, so when modeling the forming tool with a rigid shell element, the difference between the simulation result and the measured value is large. Therefore, the expected accuracy may not be obtained.
- step S110 it is determined whether or not the accuracy expected by the finite element model of the forming tool constructed in step S100 is obtained, and whether or not the model needs to be changed is determined (S110).
- the determination in step S110 compares an evaluation threshold set in advance with respect to the base material strength and the molded product size, for example, an evaluation index calculated based on the thickness increase obtained in step S100 and the molding load. You may do it.
- the evaluation index may be a value obtained by integrating the thickness increase and the molding load.
- step S110 If it is determined in step S110 that it is not necessary to change the finite element model constructed in step S100 (for example, if the evaluation index is equal to or less than the evaluation threshold), the finite element constructed in step S100. Decide to perform a molding simulation using the model. On the other hand, when it is determined that the finite element model constructed in step S100 needs to be changed (for example, when the evaluation index exceeds the evaluation threshold), the finite element model is limited based on the model setting method according to the present embodiment. Rebuild the element model.
- the forming tool is set as a finite element model composed of a surface layer and a substrate. Therefore, first, the thickness of the surface layer of the finite element model of the forming tool is determined (S120). The thickness of the surface layer may be determined based on, for example, the thickness increase obtained in step S100 and the mold dimension requirements. Then, a finite element model of the forming tool is reconstructed with the thickness of the surface layer determined in step S120, and a forming simulation is performed (S130: second forming simulation).
- a method for manufacturing a forming tool according to an embodiment of the present invention is a method for designing and manufacturing a forming tool using the above-described forming simulation method.
- the forming simulation of the metal plate can be performed with high accuracy. For this reason, it is possible to reproduce a state close to a state in which a metal plate is actually formed using a forming tool. Therefore, by using the above-described forming simulation method, it is possible to reduce the man-hours, lead time, and cost for manufacturing a forming tool.
- a forming defect such as a crack or a wrinkle associated with forming a metal plate, a dimensional accuracy defect caused by a spring back at the time of releasing from a mold after forming, and the like are analyzed.
- a forming tool based on the analysis results.
- the type of the forming tool is appropriately selected according to the method of forming the metal plate.
- a mold, a roll, and the like used for press forming such as draw forming and bending forming, roll forming, and the like.
- the configuration of these forming tools is the same as that of a general forming tool.
- the hat member shown in FIG. 1 is a molded product.
- the cross-sectional shape of the hat member, which is the molded product, was 80 mm in punch width (horizontal distance between both side walls) and 60 mm in height (distance in the vertical direction between the top plate surface and the flange surface).
- the width of the metal plate before forming was 240 mm.
- the hat member has a length of 700 mm and a shape having a curvature with a radius of curvature R of 1000 mm at the center of the width of the punch in the horizontal plane.
- As the metal plate a cold-rolled steel plate having a tensile strength of 780 MPa and a plate thickness of 1.2 mm was used.
- Comparative Example 1 As Comparative Example 1, a finite element model of a press molding die shown in FIG. 10 was created.
- the die model 22, the punch model 23, and the blank holder model 24 are modeled by rigid shell elements, and the metal plate model 11 is modeled by an elastic-plastic shell element.
- Comparative Example 2 As Comparative Example 2, a finite element model of a press molding die shown in FIG. 11 was created.
- the die model 22, the punch model 23, and the blank holder model 24 are modeled by elastic solid elements, and the metal plate model 11 is modeled by an elastic-plastic shell element.
- a cushion pin 25 is disposed below the blank holder model 24, and the wrinkle pressing pressure applied to the metal plate model 11 is applied by the cushion pin 25 via the blank holder model 24.
- the cushion pin 25 was modeled as a rigid body.
- a finite element model of a metal plate is press-molded using the finite element model of the press-molding die of Comparative Example 2, and a molded product (hat member) as shown in FIG. )
- the analysis model was a 1/2 symmetry model in consideration of the symmetry of the molded product.
- the cross section shown in the partial enlarged view of the region A in FIGS. 10 and 11 is a plane of symmetry.
- FIG. 12 shows the strain distribution in the height direction (Z direction) of the mold surface in the molding simulation.
- FIG. 12 corresponds to the R portion (broken line portion B in FIG. 11) of the die model 22 shown in FIG. From FIG. 12, it was found that distortion occurred from the surface of the mold to a thickness of about 2 mm when the metal plate was formed. From this, it was confirmed that a molding simulation considering the elastic deformation of the molding tool can be performed by modeling only the vicinity of the surface of the molding tool in contact with the metal plate as an elastic body or an elastic-plastic body. .
- Example 1 As Example 1, a finite element model of a press-molding die was created using an elastic shell element as a surface layer and a rigid shell element as a base.
- the finite element model of Example 1 is shown in FIG.
- the surface layer 12 a of the die model 12, the surface layer 13 a of the punch model 13, and the surface layer 14 a of the blank holder model 14 are elastic shell elements, the base body 12 b of the die model 12, and the punch model 13.
- a finite element model of a press mold was constructed with the base body 13b and the base body 14b of the blank holder model 14 as a rigid shell element and the metal plate model 11 as an elastic-plastic shell element.
- the thickness of the surface layer was 2 mm, and the shell element was arranged at the center of the thickness.
- the shell element of the substrate was disposed so as to contact the surface opposite to the surface contacting the surface metal plate.
- Rigid body restraint conditions were set between the surface layer 12a and the substrate 12b, the surface layer 13a and the substrate 13b, and the surface layer 14a and the substrate 14b.
- the virtual thickness of the surface shell element was 2 mm, and the virtual thickness of the base shell element was 0 mm as described above.
- Example 2 As Example 2, a finite element model of a press-molding die was created with the surface layer as an elastic thick shell element and the base as a rigid shell element.
- the finite element model of Example 2 is shown in FIG.
- the surface layer 12a of the die model 12, the surface layer 13a of the punch model 13, and the surface layer 14a of the blank holder model 14 are elastic thick shell elements
- the punch A finite element model of a pressing mold was constructed with the base body 13b of the model 13 and the base body 14b of the blank holder model 14 as a rigid shell element
- the metal plate model 11 as an elastic-plastic shell element.
- the base body 14b of the blank holder model 14 is not shown because it is hidden by the surface layer 14a.
- the thickness of the surface layer was set to 2 mm
- the shell element of the base was arranged so as to contact the surface on the opposite side of the surface contacting the metal plate.
- Rigid body restraint conditions were set between the surface layer 12a and the substrate 12b, the surface layer 13a and the substrate 13b, and the surface layer 14a and the substrate 14b.
- the virtual thickness of the shell element of the base was 0 mm as described above.
- Example 3 As Example 3, a finite element model of a press-molding die was created using an elastic solid element whose surface layer was divided into one in the thickness direction and a base body as a rigid shell element.
- the finite element model of Example 3 is the same in display as the finite element model of the mold of Example 2 shown in FIG.
- the surface layer 12a of the die model 12, the surface layer 13a of the punch model 13 and the surface layer 14a of the blank holder model 14 are elastic solid elements, the base body 12b of the die model 12, the base body 13b of the punch model 13, and the blank holder model.
- a finite element model of a press-molding die was constructed with 14 base bodies 14b as rigid shell elements and the metal plate model 11 as an elastic-plastic shell element.
- the thickness of the surface layer was set to 2 mm, and the shell element of the base was arranged so as to contact the surface on the opposite side of the surface contacting the metal plate.
- Rigid body restraint conditions were set between the surface layer 12a and the substrate 12b, the surface layer 13a and the substrate 13b, and the surface layer 14a and the substrate 14b.
- the surface layer was made into the solid element of thickness direction 1 division.
- the virtual thickness of the shell element of the base was 0 mm as described above.
- Example 4 As Example 4, a finite element model of a press-molding die was created with the surface layer as an elastic solid element divided into one thickness direction and the substrate as a rigid solid element divided into one thickness direction.
- a finite element model of Example 4 is shown in FIG.
- the surface layer 12a of the die model 12, the surface layer 13a of the punch model 13, and the surface layer 14a of the blank holder model 14 are elastic solid elements, the base body 12b of the die model 12, the base body 13b of the punch model 13, and the blank holder model.
- a finite element model of a press molding die was constructed with 14 base bodies 14b as rigid solid elements and the metal plate model 11 as an elastic-plastic shell element.
- the thickness of the surface layer was set to 2 mm, and the solid element of the substrate was arranged so as to be in contact with the surface opposite to the surface in contact with the metal plate of the surface layer.
- Rigid body restraint conditions were set between the surface layer 12a and the substrate 12b, the surface layer 13a and the substrate 13b, and the surface layer 14a and the substrate 14b.
- the surface layer was a solid element divided into one in the thickness direction.
- the substrate was a solid element divided into one piece in the thickness direction, and the thickness was 2 mm.
- Example 5 As Example 5, a finite element model of a press molding die was created by using a surface shell as an elastic shell element, a base as a rigid shell element, and sharing the nodes of the surface layer and the base shell element.
- the finite element model of Example 5 is shown in FIG. In FIG. 16, the surface layer and the substrate are overlapped for display and are not distinguished.
- the surface layer 12a of the die model 12, the surface layer 13a of the punch model 13, and the surface layer 14a of the blank holder model 14 are elastic shell elements, the base body 12b of the die model 12, the base body 13b of the punch model 13, and the blank holder model.
- a finite element model of a press-molding die was constructed with 14 base bodies 14b as rigid shell elements and the metal plate model 11 as an elastic-plastic shell element.
- the finite element model was created so that the surface layer 12a and the base body 12b, the surface layer 13a and the base body 13b, and the surface layer 14a and the base body 14b share a node.
- the virtual surface on one side that contacts the surface metal plate is subject to elastic deformation. Therefore, the virtual thickness of the surface layer is 4 mm, which is twice that of Example 1, and the virtual thickness A shell element was placed in the center of Further, the virtual thickness of the shell element of the base was 0 mm as described above.
- Example 6 As Example 6, the surface layer is made of an elastic solid element divided into one in the thickness direction, the base body is a rigid shell element, and some nodes of the surface solid element and the node of the base shell element are shared to be integrated, A finite element model of press mold was created.
- the finite element model of Example 6 is the same in display as the finite element model of the molds of Example 2 and Example 3 shown in FIG.
- the surface layer 12a of the die model 12, the surface layer 13a of the punch model 13 and the surface layer 14a of the blank holder model 14 are elastic solid elements, the base body 12b of the die model 12, the base body 13b of the punch model 13 and the blank holder model.
- a finite element model of a press-molding die was constructed with 14 base bodies 14b as rigid shell elements and the metal plate model 11 as an elastic-plastic shell element.
- the thickness of the surface layer was set to 2 mm, and the shell element of the substrate was arranged so as to contact the surface of the surface layer opposite to the metal plate contact surface.
- the surface layer 12a and the base body 12b, the surface layer 13a and the base body 13b, and the surface layer 14a and the base body 14b have a finite element model so as to share the node of the surface in contact with the base and the node of the shell element of the base, respectively.
- the surface layer was made into the solid element of thickness direction 1 division. Further, the virtual thickness of the shell element of the base was 0 mm as described above.
- Example 7 As Example 7, the surface layer is made of an elastic solid element having a thickness direction divided into one part, the substrate is made of a solid solid element having a thickness direction divided into one part, and some nodes of the surface layer solid element and some nodes of the substrate solid element are made.
- the finite element model of the press-molding die was created by sharing.
- the finite element model of Example 7 is the same as the finite element model of the mold of Example 4 shown in FIG.
- the surface layer 12a of the die model 12, the surface layer 13a of the punch model 13 and the surface layer 14a of the blank holder model 14 are solid elastic elements, the base body 12b of the die model 12, the base body 13b of the punch model 13 and the blank holder model.
- a finite element model of a press molding die was constructed with 14 base bodies 14b as rigid solid elements and the metal plate model 11 as an elastic-plastic shell element.
- the thickness of the surface layer was set to 2 mm, and the solid element of the substrate was arranged so as to be in contact with the surface of the surface layer opposite to the metal plate contact surface.
- the finite element model was created so that the surface layer 12a and the base body 12b, the surface layer 13a and the base body 13b, and the surface layer 14a and the base body 14b share the nodes of the surfaces in contact with each other.
- the surface layer was made into the solid element of thickness direction 1 division.
- the substrate was a solid element divided into one piece in the thickness direction, and the thickness was 2 mm.
- FIGS. 17A to 17E show blank holders in a molding simulation using the finite element models of press molds of Comparative Example 1, Comparative Example 2, Example 1, Example 2, and Example 3, respectively.
- the surface pressure distribution is shown.
- Comparative Example 1 the surface pressure is concentrated only in the central portion in the longitudinal direction on the side of the shrinkage flange where the thickness increase is large in the molded product, whereas in Comparative Example 2, Example 1, Example 2, and Example 3, It was confirmed that the surface pressure was distributed in the longitudinal direction including the stretch flange side.
- the surface pressure in the longitudinal direction including the stretch flange side is also present. It was confirmed that it was distributed.
- FIG. 18C shows the twist angle and the actually measured value in the molding simulation.
- Comparative Example 2 in which the forming tool is modeled by an elastic solid element and Examples 1 to 3 in which the forming tool is modeled by the above-described forming simulation method according to the present embodiment.
- the twist angle was reduced as compared with Comparative Example 1 in which the molding tool was modeled by a rigid shell element.
- the analysis accuracy of Examples 1 to 3 is equivalent to that of Comparative Example 2, and is closer to the actual measurement value than Comparative Example 1.
- Example 4 in which the surface layer is an elastic solid element and the base is a rigid solid element has the same twist angle as Example 3 in which the surface layer is also an elastic solid element. It became. Further, a finite element model is created by integrating the nodes by sharing the nodes between the surface layer and the base, and the surface layer is made of an elastic body and the base layer is made of an elastic body. The twist angle was the same as in Example 1 in which the shell element and the base were rigid shell elements.
- Example 6 in which the surface layer is a solid element and the substrate is a shell element has the same twist angle as Example 3 in which the surface layer is a solid element and the substrate is a shell element, and the surface layer is a solid element and the substrate is a solid element.
- Example 7 the same twist angle was obtained as in Example 4 in which the surface layer was a solid element and the substrate was a solid element.
- the analytical accuracy of Examples 4 to 7 was all the same as that of Comparative Example 2, and was closer to the actually measured value than Comparative Example 1.
- Table 1 The analysis time in the molding simulation is shown in Table 1 below.
- Examples 1 to 4 are the results when a molding tool is modeled by setting a rigid body constraint condition between the surface layer and the substrate, and Examples 5 to 7 are results for the surface layer and the substrate. This is a result of modeling the forming tool by integrating the nodes by sharing them.
- Comparative Example 1 in which the forming tool was modeled by a rigid shell element was the shortest
- Comparative Example 2 in which the forming tool was modeled by an elastic solid element was the longest
- the surface layer is one of an elastic body shell element, an elastic body thick shell element, or an elastic body solid element
- the base body is a rigid shell element
- a rigid body constraint condition is set between the surface layer and the base body.
- the calculation time could be greatly shortened compared to the Comparative Example 2.
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Abstract
Description
Memory)、RAM(Random Access Memory)等を備える情報処理装置によって実施され得る。また、このようなプログラムが格納された、コンピュータで読み取り可能な記録媒体も提供することが可能である。記録媒体は、例えば、磁気ディスク、光ディスク、光磁気ディスク、フラッシュメモリなどであり得る。また、上記のプログラムは、記録媒体を用いずに、例えばネットワークを介して配信されてもよい。
本発明の一実施形態に係るモデル設定方法は、有限要素法を用いて成形用工具による金属板の成形をシミュレートするための有限要素モデルをコンピュータに備えられたプロセッサにより設定する方法である。かかるモデル設定方法では、成形用工具を表す成形用工具モデルの設定において、上記成形用工具モデルのうち、金属板を表す金属板モデルと接触する金属板接触面の少なくとも一部を、弾性体または弾塑性体の特性を有する表層に設定し、上記成形用工具モデルのうち、上記表層を支持する部分を、剛体の特性を有する基体に設定することを特徴とする。モデル設定方法により設定された有限要素モデルを用いて、金属板の成形シミュレーションが行われる。以下、本発明の一実施形態に係るモデル設定方法および成形シミュレーション方法について、図1~図7Bを参照して説明する。
本発明の実施形態に係る成形用工具の有限要素モデルは、成形用工具の金属板接触面の少なくとも一部の表層が弾性体又は弾塑性体で表現され、前記表層を支持する基体が剛体で表現されているモデルである。表層および基体を合わせて一つの成形用工具の有限要素モデルが構成される。
本実施形態においては、上記のモデル設定方法により設定された成形用工具の有限要素モデルを用いて、有限要素法による金属板の成形シミュレーションを行う。成形シミュレーションには、汎用有限要素法解析ソフトが用いられる。また、成形用工具の有限要素モデルにおいては、対になる表層および基体は合わせて一つの成形用工具を表現するものであるため、基体が表層を支持し、かつ、表層と一体となって剛体変位ができるように、基体と表層との間に拘束条件を設定して基体と表層とを結合する。
上述のように、本実施形態に係る成形シミュレーション方法で用いる成形用工具の有限要素モデルは、金属板と接触し、弾性体または弾塑性体の特性を有する表層と、上記表層を支持し、剛体の特性を有する基体とを有する。これにより、金属板の成形シミュレーションを高精度かつ効率的に実行できる。一方で、成形シミュレーションで用いる有限要素モデルは、成形シミュレーション結果に要求される精度や、成形用工具の有限要素モデルの作成時間、計算時間等を考慮して、最適なモデルであるのが望ましい。
本発明の実施形態に係る成形用工具の製造方法は、上述の成形シミュレーション方法を用いて成形用工具を設計し、製造する方法である。
比較例1として、図10に示すプレス成形用金型の有限要素モデルを作成した。ダイモデル22、パンチモデル23およびブランクホルダモデル24は剛体のシェル要素、金属板モデル11は弾塑性体のシェル要素でモデル化した。
比較例2として、図11に示すプレス成形用金型の有限要素モデルを作成した。ダイモデル22、パンチモデル23およびブランクホルダモデル24は弾性体のソリッド要素、金属板モデル11は弾塑性体のシェル要素でモデル化した。ブランクホルダモデル24の下側には、クッションピン25が配置されており、金属板モデル11に負荷されるしわ押さえ圧は、ブランクホルダモデル24を介してクッションピン25により負荷される。なお、クッションピン25は剛体としてモデル化した。
実施例1として、表層を弾性体シェル要素、基体を剛体シェル要素として、プレス成形用金型の有限要素モデルを作成した。実施例1の有限要素モデルを図13に示す。実施例1では、図13に示すように、ダイモデル12の表層12a、パンチモデル13の表層13aおよびブランクホルダモデル14の表層14aは弾性体のシェル要素、ダイモデル12の基体12b、パンチモデル13の基体13bおよびブランクホルダモデル14の基体14bは剛体のシェル要素、金属板モデル11は弾塑性体のシェル要素として、プレス成形用金型の有限要素モデルを構築した。この有限要素モデルでは、表層の厚さを2mmとし、厚さの中心にシェル要素を配置した。基体のシェル要素は表層の金属板と接する面とは反対側の面に接するように配置した。表層12aと基体12b、表層13aと基体13b、表層14aと基体14bとの間には剛体拘束条件を設定した。また、表層のシェル要素の仮想厚さは2mm、基体のシェル要素の仮想厚さは上述の通り0mmとした。
実施例2として、表層を弾性体厚肉シェル要素、基体を剛体シェル要素として、プレス成形用金型の有限要素モデルを作成した。実施例2の有限要素モデルを図14に示す。実施例2では、図14に示すように、ダイモデル12の表層12a、パンチモデル13の表層13aおよびブランクホルダモデル14の表層14aは弾性体の厚肉シェル要素、ダイモデル12の基体12b、パンチモデル13の基体13bおよびブランクホルダモデル14の基体14bは剛体のシェル要素、金属板モデル11は弾塑性体のシェル要素として、プレス成形用金型の有限要素モデルを構築した。なお、図14では、表示上、ブランクホルダモデル14の基体14bは表層14aによって隠れているため示されていない。この有限要素モデルでは、表層の厚さを2mmとし、基体のシェル要素は表層の金属板と接する面とは反対側の面に接するように配置した。表層12aと基体12b、表層13aと基体13b、表層14aと基体14bとの間には剛体拘束条件を設定した。また、基体のシェル要素の仮想厚さは上述の通り0mmとした。
実施例3として、表層を厚さ方向1分割の弾性体ソリッド要素、基体を剛体シェル要素として、プレス成形用金型の有限要素モデルを作成した。実施例3の有限要素モデルは、図14に示す実施例2の金型の有限要素モデルと表示上は同じになった。実施例3では、ダイモデル12の表層12a、パンチモデル13の表層13aおよびブランクホルダモデル14の表層14aは弾性体のソリッド要素、ダイモデル12の基体12b、パンチモデル13の基体13bおよびブランクホルダモデル14の基体14bは剛体のシェル要素、金属板モデル11は弾塑性体のシェル要素として、プレス成形用金型の有限要素モデルを構築した。この有限要素モデルでは、表層の厚さを2mmとし、基体のシェル要素は表層の金属板と接する面とは反対側の面に接するように配置した。表層12aと基体12b、表層13aと基体13b、表層14aと基体14bとの間には剛体拘束条件を設定した。また、表層は、厚さ方向1分割のソリッド要素とした。また、基体のシェル要素の仮想厚さは上述の通り0mmとした。
実施例4として、表層を厚さ方向1分割の弾性体ソリッド要素、基体を厚さ方向1分割の剛体ソリッド要素として、プレス成形用金型の有限要素モデルを作成した。実施例4の有限要素モデルを図15に示す。実施例4では、ダイモデル12の表層12a、パンチモデル13の表層13aおよびブランクホルダモデル14の表層14aは弾性体のソリッド要素、ダイモデル12の基体12b、パンチモデル13の基体13bおよびブランクホルダモデル14の基体14bは剛体のソリッド要素、金属板モデル11は弾塑性体のシェル要素として、プレス成形用金型の有限要素モデルを構築した。この有限要素モデルでは、表層の厚さを2mmとし、基体のソリッド要素は表層の金属板と接する面とは反対側の面に接するように配置した。表層12aと基体12b、表層13aと基体13b、表層14aと基体14bとの間には剛体拘束条件を設定した。また、表層は、厚さ方向に1分割のソリッド要素とした。また、基体は、厚さ方向に1分割のソリッド要素とし、厚さは2mmとした。
実施例5として、表層を弾性体シェル要素、基体を剛体シェル要素とし、表層と基体のシェル要素の節点を共有することで一体化して、プレス成形用金型の有限要素モデルを作成した。実施例5の有限要素モデルを図16に示す。なお、図16では表示上、表層と基体とは重なっており、区別されていない。実施例5では、ダイモデル12の表層12a、パンチモデル13の表層13aおよびブランクホルダモデル14の表層14aは弾性体のシェル要素、ダイモデル12の基体12b、パンチモデル13の基体13bおよびブランクホルダモデル14の基体14bは剛体のシェル要素、金属板モデル11は弾塑性体のシェル要素として、プレス成形用金型の有限要素モデルを構築した。表層12aと基体12b、表層13aと基体13b、表層14aと基体14bは互いに節点を共有するように有限要素モデルを作成した。なお、この有限要素モデルでは、表層の金属板と接触する片側の仮想表面が弾性変形の対象となるため、表層の仮想厚さを実施例1に対して2倍の4mmとし、当該仮想厚さの中心にシェル要素を配置した。また、基体のシェル要素の仮想厚さは上述の通り0mmとした。
実施例6として、表層を厚さ方向1分割の弾性体ソリッド要素、基体を剛体シェル要素とし、表層のソリッド要素の一部の節点と基体のシェル要素の節点を共有することで一体化して、プレス成形用金型の有限要素モデルを作成した。実施例6の有限要素モデルは、図14に示す実施例2および実施例3の金型の有限要素モデルと表示上は同じになった。実施例6では、ダイモデル12の表層12a、パンチモデル13の表層13aおよびブランクホルダモデル14の表層14aは弾性体のソリッド要素、ダイモデル12の基体12b、パンチモデル13の基体13bおよびブランクホルダモデル14の基体14bは剛体のシェル要素、金属板モデル11は弾塑性体のシェル要素として、プレス成形用金型の有限要素モデルを構築した。この有限要素モデルでは、表層の厚さを2mmとし、基体のシェル要素は表層の金属板接触面とは反対側の面に接するように配置した。表層12aと基体12b、表層13aと基体13b、表層14aと基体14bは、表層のソリッド要素のうち基体と接する面の節点と基体のシェル要素の節点とを互いに共有するように有限要素モデルをそれぞれ作成した。また、表層は、厚さ方向1分割のソリッド要素とした。また、基体のシェル要素の仮想厚さは上述の通り0mmとした。
実施例7として、表層を厚さ方向1分割の弾性体ソリッド要素、基体を厚さ方向1分割の剛体ソリッド要素とし、表層のソリッド要素の一部の節点と基体のソリッド要素の一部の節点を共有することで一体化して、プレス成形用金型の有限要素モデルを作成した。実施例7の有限要素モデルは、図15に示す実施例4の金型の有限要素モデルと表示上は同じになった。実施例7では、ダイモデル12の表層12a、パンチモデル13の表層13aおよびブランクホルダモデル14の表層14aは弾性体のソリッド要素、ダイモデル12の基体12b、パンチモデル13の基体13bおよびブランクホルダモデル14の基体14bは剛体のソリッド要素、金属板モデル11は弾塑性体のシェル要素として、プレス成形用金型の有限要素モデルを構築した。この有限要素モデルでは、表層の厚さを2mmとし、基体のソリッド要素は表層の金属板接触面とは反対側の面に接するように配置した。表層12aと基体12b、表層13aと基体13b、表層14aと基体14bは、互いに接する面の節点を共有するように有限要素モデルをそれぞれ作成した。また、表層は、厚さ方向1分割のソリッド要素とした。また、基体は、厚さ方向に1分割のソリッド要素とし、厚さは2mmとした。
汎用有限要素法解析ソフトを用い、比較例1、2および実施例1~7の金型の有限要素モデルを用いて金属板の有限要素モデルをプレス成形し、図1に示すような成形品(ハット部材)を得る成形シミュレーションを行った。解析モデルは、成形品の対称性を考慮して1/2対称モデルとした。上記の図13~図16の領域Aの部分拡大図に示される断面が対称面である。
成形シミュレーションにより、金属板にダイおよびブランクホルダでしわ押さえ圧を負荷しながら絞り成形を実施した際のブランクホルダ面上の面圧分布について解析を行った。図17(a)~(e)にそれぞれ比較例1、比較例2、実施例1、実施例2、実施例3のプレス成形用金型の有限要素モデルを用いた場合の成形シミュレーションにおけるブランクホルダの面圧分布を示す。比較例1では、成形品において増厚が大きい縮みフランジ側の長手方向中央部にのみ面圧が集中しているのに対し、比較例2、実施例1、実施例2、実施例3では、伸びフランジ側も含めて長手方向に面圧が分布していることが確認できた。なお、図17には記載していないが、実施例4~7についても、比較例2、実施例1、実施例2、実施例3と同様、伸びフランジ側も含めて長手方向に面圧が分布していることが確認できた。
成形シミュレーションにより、成形後のスプリングバック解析を行った。図18Aおよび図18Bに示すような成形品の天板面の中央を基準としたときの天板面端部の捻れ角θを計算した。図18Cに、成形シミュレーションにおける捻れ角および実測値を示す。図18Cに示すように、成形用工具を弾性体ソリッド要素によりモデル化した比較例2と、上述の本実施形態に係る成形シミュレーション方法により成形用工具をモデルした実施例1~3とは、いずれも成形用工具を剛体シェル要素によりモデル化した比較例1よりも捻れ角が低減した。また、実施例1~3の解析精度は、いずれも比較例2と同等で、比較例1よりも実測値に近い値を示した。
成形シミュレーションでの解析時間を下記表1に示す。表1において、実施例1~4は、表層と基体との間に剛体拘束条件を設定して成形用工具をモデル化した場合の結果であり、実施例5~7は、表層と基体とで節点を共有することで一体化して成形用工具をモデル化した場合の結果である。
2 ダイ
3 パンチ
4 ブランクホルダ
10A 成形用工具
10B 成形用工具モデル
11 金属板モデル
12、22 ダイモデル
12a ダイモデルの表層
12b ダイモデルの基体
13、23 パンチモデル
13a パンチモデルの表層
13b パンチモデルの基体
14、24 ブランクホルダモデル
14a ブランクホルダモデルの表層
14b ブランクホルダモデルの基体
30 成形品
Claims (23)
- 有限要素法を用いて成形用工具による金属板の成形をシミュレートするための有限要素モデルをコンピュータに備えられたプロセッサにより設定するモデル設定方法であって、
成形用工具を表す成形用工具モデルの設定において、
前記成形用工具モデルのうち、前記金属板と接触する金属板接触面の少なくとも一部を、弾性体または弾塑性体の特性を有する表層に設定し、
前記成形用工具モデルのうち、前記表層を支持する部分を、剛体の特性を有する基体に設定する、モデル設定方法。 - 前記表層は、シェル要素、厚肉シェル要素またはソリッド要素である、請求項1に記載のモデル設定方法。
- 前記基体は、シェル要素である、請求項1または2に記載のモデル設定方法。
- 前記基体は、ソリッド要素または厚肉シェル要素である、請求項1または2に記載のモデル設定方法。
- 前記表層および前記基体で表現された前記成形用工具モデルは、前記成形用工具の表面近傍の領域を、前記金属板接触面に沿ってモデル化したものである、請求項1~4のいずれか1項に記載のモデル設定方法。
- 前記表層の厚さは、前記金属板の母材厚さの0.2~5.0倍に設定される、請求項1~5のいずれか1項に記載のモデル設定方法。
- 前記表層の厚さは、1.0~10mmである、請求項1~6のいずれか1項に記載のモデル設定方法。
- 前記成形用工具モデルのうち、前記金属板の成形時に前記成形用工具に対して荷重が集中する部分を、前記表層として設定する、請求項1~7のいずれか1項に記載のモデル設定方法。
- 複数の前記成形用工具をモデル化する場合、前記成形用工具モデルのうち少なくともいずれか1つを、前記表層および前記基体を有する有限要素モデルで表す、請求項1~8のいずれか1項に記載のモデル設定方法。
- 有限要素法を用いて成形用工具による金属板の成形をシミュレートする成形シミュレーション方法であって、
前記金属板を表す金属板モデルを設定する金属板モデル設定ステップと、
前記成形用工具を表す成形用工具モデルを設定する成形用工具モデル設定ステップと、
前記金属板モデルと前記成形用工具モデルとを用いて、前記成形用工具による前記金属板の成形をシミュレートする解析ステップと、
を含み、
前記成形用工具モデル設定ステップは、請求項1~9のいずれか1項に記載のモデル設定方法を用いて第1の成形用工具モデルを設定する第1設定ステップを含む、成形シミュレーション方法。 - 前記成形用工具モデル設定ステップは、前記成形用工具を剛体シェル要素で表した第2の成形用工具モデルを設定する第2設定ステップを含み、
前記金属板モデルと前記第2の成形用工具モデルとを用いて解析する第1成形シミュレーションを実施し、
前記第1成形シミュレーションにより得られた前記金属板の増厚量および成形荷重に基づいて、前記第2の成形用工具モデルの変更の要否を判定し、
前記第2の成形用工具モデルの変更が必要と判定された場合、前記第1の成形用工具モデルを用いて解析する第2成形シミュレーションを実施する、
請求項10に記載の成形シミュレーション方法。 - 請求項10または11に記載の成形シミュレーション方法を用いて成形用工具を設計し、製造する、成形用工具の製造方法。
- コンピュータに、有限要素法を用いて成形用工具による金属板の成形をシミュレートするための有限要素モデルを設定する処理を実行させるためのプログラムであって、
成形用工具を表す成形用工具モデルの設定において、
前記成形用工具モデルのうち、前記金属板と接触する金属板接触面の少なくとも一部を、弾性体または弾塑性体の特性を有する表層に設定し、
前記成形用工具モデルのうち、前記表層を支持する部分を、剛体の特性を有する基体に設定する、プログラム。 - 有限要素法を用いて成形用工具による金属板の成形をシミュレートするための有限要素モデルを設定する処理をコンピュータに実行させるためのプログラムを記録したコンピュータ読み取り可能な記録媒体であって、
成形用工具を表す成形用工具モデルの設定において、
前記成形用工具モデルのうち、前記金属板と接触する金属板接触面の少なくとも一部を、弾性体または弾塑性体の特性を有する表層に設定し、
前記成形用工具モデルのうち、前記表層を支持する部分を、剛体の特性を有する基体に設定するプログラムを記録したコンピュータ読み取り可能な記録媒体。 - 成形用工具による金属板の成形のシミュレーションに用いられる前記成形用工具の有限要素モデルであって、
前記成形用工具の金属板接触面の少なくとも一部の表層が弾性体または弾塑性体で表現され、前記表層を支持する基体が剛体で表現されている、有限要素モデル。 - 前記表層および前記基体で表現された前記成形用工具の有限要素モデルは、前記成形用工具の表面近傍の領域を、前記金属板接触面に沿ってモデル化したものである、請求項15に記載の有限要素モデル。
- 弾性体または弾塑性体で表現された前記表層は、シェル要素、厚肉シェル要素またはソリッド要素である、請求項15または16に記載の有限要素モデル。
- 剛体で表現された前記基体はシェル要素である、請求項15~17のいずれか1項に記載の有限要素モデル。
- 剛体で表現された前記基体は、ソリッド要素または厚肉シェル要素である、請求項15~17のいずれか1項に記載の有限要素モデル。
- 前記表層の少なくとも一部には、前記成形用工具のブランクホルダの少なくとも一部が含まれる、請求項15~19のいずれか1項に記載の有限要素モデル。
- 前記表層の少なくとも一部には前記成形用工具の凸形状部が含まれる、請求項15~19のいずれか1項に記載の有限要素モデル。
- 前記金属板から湾曲面を有する成形品を成形するための前記成形用工具の有限要素モデルにおいて、前記表層の少なくとも一部には、前記成形品の湾曲面に対応する前記成形用工具の領域が含まれる、請求項15~19のいずれか1項に記載の有限要素モデル。
- 前記表層の厚さは、1.0~10mmである、請求項15~22のいずれか1項に記載の有限要素モデル。
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JP2016538447A JP6380536B2 (ja) | 2014-07-30 | 2015-07-30 | モデル設定方法、成形シミュレーション方法、プログラム、及びプログラムを記録したコンピュータ読み取り可能な記録媒体 |
US15/318,836 US20170140081A1 (en) | 2014-07-30 | 2015-07-30 | Model setting method, forming simulation method, production method of forming tool, program, computer-readable recording medium having program recorded thereon, and finite element model |
KR1020177001897A KR101893312B1 (ko) | 2014-07-30 | 2015-07-30 | 모델 설정 방법, 성형 시뮬레이션 방법, 성형용 공구의 제조 방법, 프로그램, 프로그램을 기록한 컴퓨터 판독 가능한 기록 매체 및 유한 요소 모델 |
CN201580041377.4A CN106575314B (zh) | 2014-07-30 | 2015-07-30 | 模型设定方法、成型模拟方法、成型用工具的制造方法 |
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JP2017182265A (ja) * | 2016-03-29 | 2017-10-05 | 株式会社Jsol | 絞りプレス成形金型解析モデル生成システム及びプログラム、並びに、絞りプレス成形解析システム |
CN107330222A (zh) * | 2017-07-21 | 2017-11-07 | 吴锦 | 一种模具压边圈型面设计方法 |
JP6397149B1 (ja) * | 2018-03-28 | 2018-09-26 | 株式会社Jsol | 金型たわみモデル作成システム、および金型たわみモデル作成プログラム |
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CN107330222A (zh) * | 2017-07-21 | 2017-11-07 | 吴锦 | 一种模具压边圈型面设计方法 |
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JP6397149B1 (ja) * | 2018-03-28 | 2018-09-26 | 株式会社Jsol | 金型たわみモデル作成システム、および金型たわみモデル作成プログラム |
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JP7338774B1 (ja) | 2022-03-17 | 2023-09-05 | Jfeスチール株式会社 | プレス金型の設計方法、装置及びプログラム、並びにプレス成形品の製造方法 |
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JP7405215B1 (ja) | 2022-10-14 | 2023-12-26 | Jfeスチール株式会社 | プレス成形解析方法及び装置、プレス成形解析プログラム、プレス成形品の製造方法 |
WO2024079939A1 (ja) * | 2022-10-14 | 2024-04-18 | Jfeスチール株式会社 | プレス成形解析方法及び装置、プレス成形解析プログラム、プレス成形品の製造方法 |
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EP3151138A4 (en) | 2018-03-07 |
KR101893312B1 (ko) | 2018-08-29 |
EP3151138A1 (en) | 2017-04-05 |
JP6380536B2 (ja) | 2018-08-29 |
CN106575314B (zh) | 2020-09-15 |
JPWO2016017775A1 (ja) | 2017-04-27 |
US20170140081A1 (en) | 2017-05-18 |
KR20170023120A (ko) | 2017-03-02 |
CN106575314A (zh) | 2017-04-19 |
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