CAE System Of Sheet Metal Forming For The Whole Process Based On NX

Numerical simulation technology for sheet metal forming has now widely used inautomotive, appliance and hardware industry, that results in the application of manycommercial finite simulation software for sheet metal forming, such as Autoform,Dynaform, PAM-Stamp2G and so on. But, all these foreign commercial software havetheir own platforms, and have to transfer data format between different platforms whenthey are used. Some software such as Dynaform and PAM-Stamp2G are inefficient andhard to use. So, research on numerical simulation for sheet metal forming directly on CADplatform is meaningful, it can take full advantage of the characteristics of CAD function,make the simulation synchronous for all forming process. That improves the practicalityof the software greatly.This research is supported by the National NC Specific Project Stamping diedevelopment of whole body side, fender and interior of new environmentally friendlymaterials in C-class car (No.2009ZX04013-031). With the current software FAW3.0, thepurpose is to develop a system with perfect function, offering a method to simulate thewhole process in sheet metal forming.This paper introduced the current research status of finite technology in sheet metalforming, and the problems in CAD/CAE integration. In analysis of the defect of thecurrent system FAW3.0, this paper designed the structure of the new system FAW4.0withthe mature technology of NX application. The new system has a complete function ofsimulation for the whole processes in sheet metal forming, including pre-bending, gravityeffect, drawing, trimming, springback, flanging and so on. It made the simulation directlycompleted in the product, and is compatible with blank and trim line unfolding systems onNX, constituting a big system faced to product design, process assist design, andsimulation of sheet metal forming.To solve the problem of efficiency caused by assembly in FAW3.0, this paperproposed a none-assembly CAE simulation method, improving the efficiency greatly. Inthe none-assembly environment, it solved the main problem of position, measuring andanimation of the tools by using facet body. Also, it complete the parameterization, data management, and synchronizing updating in the new system, making the stampingforming design and analysis process synchronized.To meet the needs of the simulation application, this paper come up with a SelectableQuick Simulation method, and offered a function of space surface meshing. Suppose thatthe local region of the part has little change between two processes, then we can take theproduct model in the pre process as the blank for the process followed, so, the wholeprocess or the local region of the part can be taken out to analyze alone, thus improvingthe speed of the simulation greatly.At last, this paper takes products in automotive panel and appliance as examples, thesimulation result proves that the new system is effective and useful in the whole processand selectable quick simulation of sheet metal forming.