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Published Article / Rapid and reliable methods for component development and economic manufacturing layout are today crucial factors for the application of press tooling techniques in mass production of automotive industry components. The use of Finite Element Analysis (FEA) based forming simulation can provide a more detailed insight into the real behaviour of a structure. An LS-DYNA finite element model was developed to analyse the material behaviour during the piercing process of a drainage hole for a shock absorber seat. The simulation is intended to simulate tearing that occurs during the manufacturing stage. Once the current punch produces the observed tearing we can modify the punch to eliminate the problem.

A blankholder is used to hold the edges of metal sheet while it is being formed by a matrix and a punch. An efficient way to design a stamping die is to integrate the blankholder plate into the die structure. This would eliminate the time and cost to manufacture blankholder plates. The integrated structure is called integrated blankholder. The main focus of this thesis is structural analysis and optimization of the integrated blankholder. The structural analysis of the integrated blankholder model (used for the production of doors of Volvo car model V70) is performed using Hypermesh and Abaqus. The FE-results were compared with the analytical calculations of the fatigue limit. To increase the stiffness and reduce the stress levels in the integrated blankholder, topology and shape optimization is performed with Optistruct. Thereafter, a CAD model is set up in Catia based on the results of optimization. Finally, structural analysis of this CAD model is performed and the results are compared with the original results. The results show reduction in stress levels by 70% and a more homogeneous stress distribution is obtained. The mass of the die is increased by 17 % and in overall, a stiffer die is obtained. Based on the simulations and results, discussion and conclusions are formulated.

Thesis (MScEng)--Stellenbosch University, 2002. / ENGLISH ABSTRACT: The role of the computer has changed from a calculation tool to a tool that supports human thinking. In this thesis fundamental aspects of the Finite Element method are mapped to an object model with a well defined structure which provides for local and distributed analysis work. To achieve this the following was investigated: • An object-oriented framework for the Finite Element analysis method • An associated graphical user interface that enables the user to create and modify Finite Element models in an effective way • Requirements for the sharing of analysis information in a communication network Proposed solutions are implemented in a pilot application which indicates their potential. / AFRIKAANSE OPSOMMING: Die rol van die rekenaar het verander vanaf 'n gereedskapstuk wat berekening doen na 'n gereedskapstuk wat menslike denke ondersteun. In hierdie tesis word die fundamentele aspekte van die Eindige Element metode oorgedra na 'n objek model met 'n goed gedefinieerde struktuur wat lokale en verspreide analisering werk ondersteun. Om dit te bereik is die volgende ondesoek: • 'n Objek orienteerde raamwerk vir die Eindige Element metode • 'n Geassosieerde grafiese raamwerk wat die gebruiker in staat stelom objekte te skep en te verander • Vereistes vir die deel van analise inligting in 'n kommunikasie netwerk Die voorgestelde oplossing is geimplimenteer in 'n loodsimplementering wat die voordele van die benadering uitlig.

published_or_final_version / Civil and Structural Engineering / Doctoral / Doctor of Philosophy

published_or_final_version / Civil Engineering / Doctoral / Doctor of Philosophy

published_or_final_version / Civil Engineering / Doctoral / Doctor of Philosophy

published_or_final_version / Civil Engineering / Doctoral / Doctor of Philosophy

published_or_final_version / abstract / Civil Engineering / Doctoral / Doctor of Philosophy

published_or_final_version / Mechanical Engineering / Doctoral / Doctor of Philosophy