Wisselink, H.H.

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University of Twente Research Information

1.7 FEM Simulation of the forming of parts from thick sheetH.H. WisselinkCluster 1. Modelling of forming of metal and laminate products, project MC1.98056University of Twente, Applied MechanicsP.O. Box 217, 7500 AE Enschede, The NetherlandsIntroductionAccording the projectplan the forming of a thick sheetmetal part typical for DAF will be investigated. The bat-teryboxbracket (Figure 1) has been chosen, which isalready over ten years in production and proved to becritical. This part is fixed with bolts to the chassis ofthe truck and supports the batterybox (Figure 2). Theinitial thickness of the blank is 5mm. The length of thepart and the hole pattern can change, depending onthe trucktype.Figure 1: BatteryBoxBracket.The production process consists of 5 steps. First theflat blank is bended (± 90 deg.). Next the part is drawnin two stages. Afterwards the holes are punched in twosteps. All steps are performed in one press stroke.Figure 2: Truck with batterybox.ObjectivesThe first three production steps of the battery-boxbracket will be investigated using FEM simulations.This will give more insight in the drawing of this andsimilar parts, which can lead to an improved process-design. Furthermore the consequences of the intro-duction of high strength steels can be studied.ResultsThe tools have been created from paper-drawings in asuitable format for FEM simulations (These tools weredesigned before the CAD era). Luckily the tools arerelatively simple and symmetric.Some first simulations have been performed using theshell elements of DiekA to check the tools and to getfamiliar with the specific process (Figure 3).Figure 3: Thickness after first draw [mm].Future workThe radii of the tools used for the drawing of this partare 8 and 10 mm, which is of the same order as thesheet thickness. Therefore it has to be investigatedwhether the assumptions commonly used for simula-tions of thin sheet are still valid. Can shell elements,which take into account the membrane and bendingstiffness and neglect transverse shear, still be used orare solid elements necessary? Furthermore the simu-lation results have to be validated.Contact info:h.h.wisselink@ctw.utwente.nl

FEM simulation of the forming of parts from thick sheet

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