The Diploma thesis describes the implementation of innovative production of protective liner to the manufacturing company. The liner is manufactured in sizes of nominal diameter DN 200 - DN 500. The material is low-alloy steel EN 10216-2 10CrMo9-10. For the production innovation, the technology of pipe end flaring by a movable mandrel was chosen. Verification of the functionality of this technology was performed using analytical calculations and numerical simulation of FEM. The results of numerical methods were compared with the results of a practical experiment. The experiment was performed on 5 test specimens with a diameter of 273 mm. The machine device was a hydraulic press with a nominal force of 2000 kN and equipped with pressure and position sensors. The experimentally obtained values of force and the tool path dependence were similar with the values of FEM simulation. The difference in the value of the force in the maximum tool path was 290 kN. The flared diameter was formed to a value of 319 mm. This value corresponds to 16.5% of increased nominal diameter, which is sufficient from design point of view. Non-destructive tests ruled out the presence of crack defects on the flared diameter. According the new set up working procedure was produced the first real part. Significant financial savings of CZK 3.5 - 5.3 million / year were quantified in the technical and economic evaluation. Return on necessary investments is between the 9th - 14th manufactured pieces (approx. 15% of the annual production volume). In conclusion, innovation has promising results and will be issued by the company into the production process.

The thesis proposes a concept of manufacturing the folding meter lock. The part is made from DC01+LC steel of 0,3 mm thickness. The series size is 100 000 pcs/year. A forming in a progressive combination tool combining shearing, bending and stamping was chosen for the production, based on the analysis of possible solutions. The tool, designed on the basis of literary research of used technologies, produces the part in eleven steps exerting maximal force of 38,5 kN. The production will take place on an eccentric press LEN 40 C. The market price of 3,38 Kč for one piece was established by the technical and economic evaluation.

The project drawn up within the framework of engineering studies in discipline Manufacturing technology (2303T002) presents a proposal for processing a single part – the part is made of sheet steel number S420MC – by blanking, bending and stamping. On the basis of a literary exploration of given problems several variants of processing a part was propounded in order to be made in just one tool. The transfer combined die is fixed in crank press WAINGARTEN ARP 80 with 800 kN nominal force. All functional parts are made of heat treated tool steel number 19 573.3 according to drawing documentation. Lower functional parts of tool (blanking die, stamping die and bending tool) are made as divided.

The aim of this diploma thesis is to propose a production technology of a given part based on technological and economic factors. At first it is found, if the part is producible by fineblanking. The theoretical part of the diploma thesis is concerned with the description of the conventional sheet metal cutting theory, fineblanking theory and bending theory. In the practical part of the diploma thesis, four variants of cut-in plan are dealt with including the selection of the optimal one based on technological and economic calculations. It is the production of a PULL REAR iron made of the steel sheet 11 320.21, thickness of 3 mm and a production run of 75 000 pieces per year.

This thesis submits a proposal production technology of single parts from sheet steel No. 11 305, thickness of 2 mm, made from a semi-finished product with a diameter of 246 mm, production run of 50 000 pieces per year. To manufacture the component a technology of hydromechanical drawing is proposed. On the basis of a literary study and calculations a drawing tool was designed, fixed in hydraulic press LPS 4000. To prepare a semi-finished product, flange trimming, and hole punching, a sheet metal cutting is used.

Based on study of documents supplied by PWO Unitools a.s. and on advices of design office staff, tool for forming flanges was designed. This tool was then manufactured and it has been used for carrying test of creating flanges of various diameters from high-strength steels. During these tests, the following parameters were optimized – force of upper and lower blank holder and the height of the main guides. Threads were created into these drown flanges. These threaded joins were later tested for maximum torque and maximum compressive strength.

This master’s thesis conducted within the master's degree focuses on the design of production for component, which is a wall-mount the TV. The blank is sheet steel DC03 and the annual production is 300,000 pieces. After exploring possible options of manufacturing was chosen compound tool. In the theoretical part were explored technology used cutting and bending. Further, the manufacturing process and tool design were made. The suitability of the solution was verified by economic evaluation.

As part of the development process for new stamping dies, in the automotive sheet metal forming (SMF) industry, the majority of all forming operations are simulated with the Finite Element Method (FEM) before the dies are manufactured. Today, these simulations are conducted with rigid tools under the assumption that there are no tool deformations. However, research shows that tool deformations have an influence on the finished product. In real production these deformations are compensated by manual rework during the try-out. Additional reason for simulating with rigid dies is that there are non-existing simulation methods elaborated for elastic stamping dies. Also, simulation of elastic tools requires high computational power.     Since simulations today are performed with rigid stamping dies the purpose of this work is to investigate the conditions of how to conduct SMF-simulations with elastic stamping dies. The object that will be studied is a stamping die for a Volvo XC90 inner door used in a single-action press. This work is part of the development to minimize the manual rework, with the goal to compensate for tool deformations in a virtual environment.    Results for rigid stamping dies in LS-Dyna was compared to currently used AutoForm as a pre-study. A simple model was then created to find a suitable method while using elastic stamping dies. The developed method was used for an industrial size stamping die.     Since there are little amount of research performed on simulations using elastic stamping dies, elasticity and complexity were gradually introduced into the FE-model. As a first step, only the punch was included as an elastic solid. Secondly, the die was added. Finally, the entire die was simulated as elastic together with the hydraulic cushion of the press. When the FE-model worked as expected a suitable method for minimizing the simulation time with acceptable results was studied.     Comparisons of measured- and simulation results show a high correlation. To improve the results from the FE-model factors such as press deformations, advanced friction models, etc. should be included.    Conclusions from this work shows that it is possible to perform SMF-simulations with elastic stamping dies. As the computational time normally is high this work also presents a method first step to reduce the computational time with acceptable results. Comparisons between simulations with rigid and elastic stamping dies proves that there are significant differences in the outcome of the two methods. / Reduced Lead Time through Advanced Die Structure Analysis - Vinnova

In product development there is still potential to decrease lead times with faster and more accurate simulations. The objective of this thesis was to study whether Finite Element (FE) simulations using explicit LS-DYNA to extract reaction forces from sheet metal forming tools during forming, could be used to improve existing FE models in sheet metal forming software AutoForm.To begin with, the solid CAD-model of the stamping dies were meshed with tetrahedral elements in CATIA and imported into LS-DYNA. In combination with sheet mesh and milling surface meshes from AutoForm, an explicit model was realized. Contacts between sheet mesh and milling surface meshes used the so-called sheet forming contact. The resulting reaction forces were extracted and used in a simulation using the AutoForm software. Resulting simulation was compared to a scan of the physical sheet metal after forming.The direct transfer of reaction forces from LS-DYNA to AutoForm did however not result in the same pressure distribution in AutoForm. The AutoForm simulations using results from LS-DYNA were slightly worse than standard AutoForm simulations.Further work is needed to try and perhaps implement an implicit solution after an initial explicit solution. / Inom produktutveckling finns möjligheter att förkorta ledtider genom snabbare och mera korrekta simuleringar. Syftet med detta arbetet var att undersöka huruvida resultat från explicit LS-DYNA kunde användas för att förbättra nuvarande plåtformningssimuleringar i AutoForm.Den solida CAD-modellen av verktyget meshades med tetraediska element i CATIA och importerades till LS-PrePost, tillsammans med fräsytsmeshar och plåtmesh från AutoForm. Kontakter etablerades mellan plåt och fräsytsmeshar med så kallad sheet forming contact. Modellen löstes sedan explicit. Resulterande reaktionskrafter på plåthållare exporterades till AutoForm och implementerades där. Resulterande simulering jämfördes mot en inskannad fysisk plåt efter plåtformning.Direkt implementering av reaktionskrafter på plåthållaren i AutoForm gav resultat som avvek mer mot inskannad plåt än nuvarande simuleringsstrategi. Direkt implementering av reaktionskrafter gav heller inte en tryckfördelning som liknade den som rapporterades av LS-DYNA.Mer arbete krävs för att om möjligt implementera en implicit lösning efter en initial explicit lösning.

In today’s car manufacturing industry, sheet metal forming is a important process that takes preparation, which is time consuming and complex when new processes are made. When new metal grades and alloys are provided to the industry, tests are conducted to determine it’s behaviour and strengths. This gives the data for complex material models that can approximate the metal behaviour in an accurate way in a simulation environment. One of the unknown factors from tests is the friction coefficient on the sheet metal. The software Triboform is able to provide an adaptable friction coefficient model that depends on multiple simulation and user input conditions. The problems that occur when acquiring data for the material model is that testing is time consuming and the friction model has to be adjusted to give accurate results. At Volvo Cars there are two material models used with their different advantages, BBC 2005 and Vegter 2017.The purpose with this work is to compare the two material models using the Triboform friction models implemented to see if any combination provides accurate simulation results and then create recommendations for which model is best suited for different cases. Some side studies is also done with an older Vegter model, a strain rate sensitive BBC 2005 model and a Triboform model on all simulation parts.The purpose is achieved by implementing the Triboform model in Autoform and run a simulation of a Limiting Dome Height (LDH) test with both material models and compare the results with experimental data for several different materials. The data that is directly compared from the LDH test is the major and minor strain from two perpendicular sections at four different stages and also the force from the punch tool. The material models will be evaluated by how it manages to mimic the strain behaviour of the metals and how it estimates the punch force.The results point towards an improvement of the accuracy for most of the metals tested and BBC 2005 is the better model if there’s available biaxial data from tests, Vegter 2017 is decent if there’s not. However Vegter 2017 is not a good option for aluminum alloys simulations when the punch force is compared. Side study also shows that Vegter 2017 is bit of a downgrade when it comes to strain values, compared to the old Vegter.The work, in summary shows a dynamic friction model can improve the accuracy for strain predictions in the simulation process. If there’s biaxial yield data available for the metal or if it’s an aluminum alloy, BBC 2005 is the superior choice, but if only tensile tests are available for metals, Vegter 2017 is a decent choice for some cases. / I dagens bilindustri är plåtmetalformning en viktig process som kräver förberedelser som är tidskonsumerande och komplex när nya processer tillkommer. När nya metallslag kommer in till industrin, så utförs tester för att avgöra dess egenskaper och styrka. Denna testdata används till materialmodeller som kan approximera metallens beteende på ett noggrant sätt i en simuleringsmiljö. Den okända faktorn från dessa test är friktionskoefficienten på plåten. Programvaran Triboform är kapabel att göra en dynamisk friktionsmodel som beror på användar- och simuleringsdata. Problemen som uppstår vid framtagning av data är att det är tidskonsumerande och flera simuleringar måste göras för att bestämma friktionen. Volvo Cars använder sig av två modeller med olika fördelar, BBC 2005 och Vegter 2017.Syftet med detta arbete är att jämföra de två materialmodellerna med Triboform modeller implementerat för att se om de påverkar noggrannheten i simuleringar och sedan förse rekommendationer för vilken modell passar bäst för olika fall. Några sidojobb i studien som görs är en jämförelse med gamla Vegter modellen, ett test med en modell som är känslig för töjningshastighet och test med att implementera Triboform modellen på alla pressverktyg.Detta utförs med att implementera Triboform modellerna i Autoform och köra en simulering på ett LDH-test med båda materialmodeller och jämföra resultaten med experimentell data för flera olika metaller. Data som skall jämföras från LDH-testet är första och andra huvudtöjningen i två vinkelräta sektioner i fyra processsteg och stämpelkraften genom hela processen. Modellerna kommer evalueras genom hur de lyckas imitera töjningens beteende och hur den estimerar stämpelkraften.Resultaten pekar mot en förbättring när Triboform är implementerat i simuleringar för de flesta metaller som ingår i testen och BBC 2005 är den model som föredras om det finns tillgänglig biaxiel spänning data från tester, Vegter 2017 är en duglig modell om dessa data inte finns. Vegter 2017 är dock inte ett bra alternativ när det kommer till jämförelse av töjning och stämpelkraften för aluminium. Sidojobb med gamla Vegter visar att den nya Vegter 2017 inte är en direkt förbättring med hänsyn till noggrannheter av krafter och töjningar.Arbetet visar att en dynamisk friktionsmodel kan förbättra prediktering av töjningar i simuleringar. Om det finns biaxiel data för metallen eller om det gäller att simulera aluminium är BBC 2005 det bättre altermativet, om det endast finns dragprovsdata för metallen så är Vegter 2017 duglig för vissa fall.