Simulation Of Crash Impact On A Formed Sheet Metal Using Hypercrash And Radioss

Muhammad Nabil, Ab Kadar (2015) Simulation Of Crash Impact On A Formed Sheet Metal Using Hypercrash And Radioss. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Sheet metal forming is one of the most widely used manufacturing processes for the fabrication of a wide range of products in many industries. The reason behind sheet metal forming gaining a lot of attention in modern technology is due to the case with which metal may be formed into useful shapes by plastic deformation processes in which the volume and mass of the metal are conserved and metal is displaced from one location to another. Deep drawing is one of the extensively used sheet metal forming processes in the industries to have mass production of cup shaped components in a very short time. Improving the accuracy of virtual prototypes helps to shorten product development times and reduce the number of physical prototypes required. One way in which the accuracy of crash analysis can be improved to include the effects of forming in material properties. Forming to crash method to rapidly estimate the formed properties and reduce the time taken to conduct the analysis during concept design. A cup as the model was developed for modelling the process from forming simulation to crash simulation. The material properties in a component of the steel DP600 were experimentally characterized. The influences of stress, strain and pre-damage caused by forming on the crash behavior were investigated and analyzed. A general material model which describes and damage was developed and implemented for forming and crash simulation. Finite element analysis software RADIOSS is used to simulate the process in crash simulation.

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