Thermo Thermo- -mechanical coupled simulation of hot forming mechanical coupled simulation of hot forming

processes considering die cooling processes considering die cooling

M. Medricky

, R. Struck

, C. Sunderktter

, D. Lorenz

, P. Olle

, B.-A. Behrens

Volkswagen Group Research, Wolfsburg

DYNAmore GmbH, Stuttgart

Institute of Metal Forming and Metal-Forming Machines, Hannover

2 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Agenda
1. Motivation
2. Objectives
3. State of the art
4. Considering die cooling
1. Methods
2. Experimental tool
3. Mass production tool
5. Conclusions and outlook
3 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Agenda
1. Motivation
2. Objectives
3. State of the art
4. Considering die cooling
1. Methods
2. Experimental tool
3. Mass production tool
5. Conclusions and outlook
4 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Deployment of hot formed high strength steels
Motivation
18%
30%
25%
12%
15%
percent by weight
140 MPa
180 - 240 MPa
260 - 300 MPa
300 - 420 MPa
1000 Mpa
Yield strength
source: Cordes et. al. EuroCarBody Award 2005
VW Passat B6
15 % of hot
formed steel
!
5 as of 11/12/09 group research: K-EFW/F (M. Medricky)
VW VW Tiguan Tiguan
VW VW Passat Passat CC CC
outer: hot formed
inner: HSS
tailored blank
inner: HSS
source: Thiele/Hahn/Lamprecht/Hahn
Audi A4 Audi A4
outer: hot formed
tailored blank
Audi Q5 Audi Q5
inner: HSS
outer:
partially press hardened
Example hot formed parts B-pillar
Motivation
inner: HSS
(conventional)
6 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Agenda
1. Motivation
2. Objectives
3. State of the art
4. Considering die cooling
1. Methods
2. Experimental tool
3. Mass production tool
5. Conclusions and outlook
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7 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Objectives
Method Experimental
tool
Mass production
tool
Part
development
Construction
Method Hot forming
simulation with
cooling system
Mass production
tool
Part
development
Construction
SOP
SOP
Hot forming
simulation
8 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Frontloading and achievable benefits
Objectives
Virtual optimization of the tool design
Reducing try out through frontloading effects (time, cost)
Optimizing process time (quenching)
Virtual tuning of local material properties (quality)
100%
virtual press shop
Frontloading
100%
actual press shop
SOP
source: Liebig
9 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Agenda
1. Motivation
2. Objectives
3. State of the art
4. Considering die cooling
1. Methods
2. Experimental tool
3. Mass production tool
5. Conclusions and outlook
10 as of 11/12/09 group research: K-EFW/F (M. Medricky)
State of the art
Friction
Friction
Matrial law
Matrial law
Thermal values
Thermal values
Yield loci, flow curve,
r-values, strain
rate,
Yield loci, flow curve,
r-values, strain
rate,
Emissivity, conductivity ,
specific heat
Emissivity, conductivity ,
specific heat
Transitional values
Transitional values
Material law
Material law
CCT - diagramm,
CCT - diagramm,
Cooling design
Mechanical simulation
Material properties
Thermal simulation
Phase transition
Energy dissipation
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Thermal strains
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Cooling simulation T
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State of
the art
11 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Agenda
1. Motivation
2. Objectives
3. State of the art
4. Considering die cooling
1. Methods
2. Experimental tool
3. Mass production tool
5. Conclusions and outlook
12 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Sensitivity analysis
Considering die cooling
Contact pressure (MPa)
Hot blank
Heat transfer (tool surface)
Heat flow
Conductivity
(tool)
Thermal convection
(cooling channel w/ water)
Thermal conductivity (W/mK)
Thermal convection (W/mK)
Parameter Values
1, 5, 10, 15, 20, 25, 30, 35, 40
1, 5, 10, 20, 50, 66, 80, 110, 130
1, 50, 500, 1000, 6000, 9000, 20000, 50000
resultant temperature in single node
13 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Example after 20 s of quenching
Considering die cooling
low
pressure
high pressure
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(W
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convection (W
/m
K)
pressure increase
convection increase
conductivity increase
14 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Agenda
1. Motivation
2. Objectives
3. State of the art
4. Considering die cooling
1. Methods
2. Experimental tool
3. Mass production tool
5. Conclusions and outlook
15 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Die model generation
Methods
1. Die surface geometry accurately
modeled with shell elements
2. Die volume geometry modeled with
volume elements
3. Shell and volume mesh coupled with
contact definition
Heat transfer from blank to
die surface shell by thermal
contact
Heat dissipation into the
dies by thermal contact
between shell and volume
mesh
16 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Solution methods
Methods
Cooling simulation starts with the final
geometry of the forming simulation
3 different solution methods are possible
1. Thermal only simulation;
tools rigid and fixed
2. Thermal-mechanical coupled with rigid
tools; tool is loaded with force
3. Thermal-mechanical coupled with elastic
tools; tool is loaded with force
All methods can use contact between
tool surface and volume
Heat
Heat
Load Load
Elastic Elastic
Heat
Heat
Load Load
Rigid Rigid
Heat
Heat
Rigid Rigid
1. 1.
2. 2.
3. 3.
17 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Cooling channels
Methods
There are different possibilities to account for
cooling passages
Temperature boundary condition
Convective boundary condition
Application of new bulkflow feature
Convective heat transfer coefficients
From CFD simulation
Bulkflow feature is the simplest way to consider
cooling systems in a thermal die analysis
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18 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Agenda
1. Motivation
2. Objectives
3. State of the art
4. Considering die cooling
1. Methods
2. Experimental tool
3. Mass production tool
5. Conclusions and outlook
19 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Experiments
Experimental tool
Variation of several process parameters within the process chain
Variation of tool material / cooling and heating etc.
Analysis of measuring data, mechanical properties, microstructure etc.
cooled
tool part
heated
tool part
20 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Simulation model
Experimental tool
Developing a process on the simplified model
Revealing and eliminating possible problems
Comparing with the real process
Evaluation of the results
Deriving the process for mass production tool
21 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Agenda
1. Motivation
2. Objectives
3. State of the art
4. Considering die cooling
1. Methods
2. Experimental tool
3. Mass production tool
5. Conclusions and outlook
22 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Functional description splitting the hot forming process
Mass production tool
Heating up Transfer Gravity Closing Pressing + Quenching Opening Removing
Waiting
Repeating the cycle
In reality one process step at one machine
23 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Procedure Building the simulation model
Mass production tool
IGES CAD CAE
Removing unnecessary parts like
clamping and intermediate
plates, frames, bolts, nuts, pipes,
sealing, pads, fixtures, etc
Deleting small unimportant holes
for bolts and handles
Exporting in the IGES format Meshing in Hypermesh, Medina,
and finishing in LS-Dyna
Building the LS-Dyna Model
24 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Pitfalls Building the simulation model
Mass production tool
High complexity of the CAD models - necessity of
cleaning from unnecessary parts
Complexity of the cooling channels - necessity of
partial simplification
Application of Bulkflow elements not possible -
nonsymmetric matrix resulting in too much
memory requirement - necessity of applying the
convection cooling method
The thermal tied contact simplifies the meshing
process experience for obtaining satisfactory
results necessary
25 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Agenda
1. Motivation
2. Objectives
3. State of the art
4. Considering die cooling
1. Methods
2. Experimental tool
3. Mass production tool
5. Conclusions and outlook
26 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Conclusions and Outlook
Demand for precision increase in prediction of hot formed part
properties
Development of simulation process containing cooling systems
Creation of experimental tool model and examining the method
feasibility
Creation of mass production tool model and examining the method
feasibility
Thermal tied contact for meshing simplification is applicable
Bulkflow not applicable for complex tools
Convection heat transfer in cooling channels used instead
Comparison with the real mass production process
Further development of the bulkflow method
27 as of 11/12/09 group research: K-EFW/F (M. Medricky)
Thank you