Accuracy in simulation by Finite Element Method
Description
Forming simulation by means of Finite Element Method (FEM) is used as an aid in component development and also to confirm a manufacturing concept arrived at by the feasibility study. The simulation provides a realistic representation of the hydroforming process including possible upstream forming operations such as bending, reduction, and pre-forming. Simulation allows the customer to decide early on in the project whether the component can be produced or whether further modifications are required.Die engineering that follows also involves a linear FEM simulation. This simulation helps in determining the stress/strain distribution, pre-forming requirements, and the localization of strain peaks in the die. In this way, die manufacturing can begin and subsequent prototyping can take place with an optimized component and a die design confirmed by FEM.
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Component failure by wrinkle formation in the initial simulation
The finished hydroformed component at the end of the optimization process.
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Feasibility studies and simulation