Training course

Materials technology for forming processes

8 hours

That the participant understands the fundamentals, advances and trends in the classification of advanced materials used in sheet metal forming processes, as well as the key mechanical properties to improve their processing.

Manufacturing engineers, designers, area managers and technical specialists seeking to increase and strengthen their knowledge in sheet metal forming processes.

Introduction

1.1. Evolution of materials for forming processes

1.2. HSS, AHSS and UHSS steels

1.3. Aluminum alloys

1.4. New trends (3rd generation)

Fundamental concepts of stress and strain

2.1. Tensile test under ASTM-E8 standard

2.2. Mechanical properties

2.3. Engineering stress-strain curve

2.4. True stress-strain curve

2.5. Stricture (Necking)

Hardening and formability parameters

3.1. K resistance coefficient

3.2. Hardening exponent n

3.3. Bauschinger effect

Anisotropy in sheets

4.1. Origin of anisotropy

4.2. Evaluation of anisotropy

4.3. Effect of anisotropy in forming processes.

4.4. Normal and planar anisotropy

Training course

Sheet metal forming processes

32 hours

That the participant knows and understands the different operations used for the forming of sheets, as well as the theoretical foundations necessary to improve their results.

Process and manufacturing engineers, die designers and technical specialists seeking to increase and strengthen their knowledge in sheet metal forming processes.

Classification of forming processes

1.1. Compression forming processes

1.2. Bending forming processes

1.3. Stretch forming processes

1.4. Cutting forming processes

1.5. Combined forming processes

Bending process

2.1.Theoretical foundations of the bending process

2.2.Bending moment

2.3.Bending force

2.4.Bending radius

2.5.U and V bending process

2.6.Tolerance in the bending process

2.7.Clearance between die and punch

2.8. Springback

2.9. Practical application examples

Deep drawing processes

3.1. Theoretical foundations of the deep drawing process

3.2. Deep drawing capacity

3.3. Stuffing operations

3.4. Calculating the blank size

3.5. Defects during the stuffing process

3.6. Practical application examples

Cutting and punching process

4.1. Theoretical foundations of the cutting and punching process

4.2. Cutting and punching process overview

4.3. Quality in cutting processes (burr)

4.4. Punch force

4.5. Material economy

4.6. Fine punching and cutting process (shaving)

4.7. Practical application examples

Other processes

5.1. Stretch forming

5.2. Spinning forming

5.3. Dimpling forming

5.4. Practical application examples


Training course

Plasticity applied to sheet metal forming processes

24 hours

That the participant knows and understands the concepts of plasticity and its application in metal forming problems

Process and manufacturing engineers, finite element simulation specialists and teachers who wish to expand their knowledge of plasticity and advanced phenomena that occur during the sheet metal forming process.

Fundamentals of plasticity

1.1. Introduction

1.2. Experimental observations on one-dimensional plasticity

1.3. Elastic and plastic region

1.4. Yield stress

1.5. Strain-hardening

1.6. Hysteresis

1.7. Bauschinger effect

1.8. Instabilities in one-dimensional plasticity (necking)

1.9. Anisotropy

Hardening models

2.1. Isotropic hardening models

2.2. Kinematic hardening models

2.3. Isotropic-kinematic hardening models

2.4. Determination of hardening parameters

2.5. Influence of hardening models on springback

2.6. Variation of Young's modulus in AHSS steels

Yield surfaces

3.1. Isotropic yield surface

3.2. Anisotropic yield surface

3.3. Polynomial yield surfaces

3.4. Convexity evaluation

3.5. Plastic multiplier (flow rule)

3.6. Experimental tests to define yield surfaces

3.7. Evolution of anisotropy

3.8. Changes in the yield surface

Applications in finite element simulation.

4.1. Case study: Drawing test for anisotropy evaluation.

4.2. Case study: Hat-shape testing for spring-back evaluation.

4.3. Case study: Hole-Expansion test for evaluating anisotropy evolution.

Training course

Simulation of Forming Processes with LS-DYNA

24 hours

The objective of this course is for the participant to understand the characteristics of the LS-DYNA simulation software and its differences with implicit finite element programs. Subsequently, the participant will learn the procedure required to perform a basic forming analysis, applied specifically to sheet metal bending. Before simulating incremental stamping processes, the participant will learn how to set up single-step analyses. Finally, the participant will be introduced to the eZ-setup module within LS-PrePost, a tool that allows the automated configuration of multi-operation processes, including stages such as gravity, clamping, forming, trimming, edging, tipping , and springback.

Process engineers, designers, and technical specialists interested in sheet metal forming process simulation.

1. Introduction to LS-DYNA

1.1 History and vision

1.2 Help Resources

1.3 The LS-DYNA deck (file.k) and its syntax

1.4 Handling units

1.5 Equation of Motion: Implicit vs. Explicit

1.6 Explicit time step calculation

1.7 Mass Scaling

2. Introduction to LS-PREPOST

2.1 Meshing

2.2 Application of boundary conditions

2.3 Application of loading conditions

2.4 Review of results

2.5 Stress Test Modeling

3. Material models for sheet metal forming

3.1 Isotropic Plasticity

3.2 Anisotropic Plasticity

3.2 Effect of anisotropy in forming processes

3.3 Generation of the elastoplastic curve

3.4 Stress-strain curve extrapolation models

4. Simulation of the bending process

4.1 Geometry generation

4.2 Punch displacement curve

4.3 Contact between parts

4.4 Selecting and configuring the material model

4.5 Solution Controls

4.6 Review of results

4.7 Springback

5. One-step stamping simulation

5.1 Introduction

5.2 Meshing the piece

5.3 Selecting and configuring the material model

5.4 Solution Controls

5.5 Review of results

5.6 Generation of the blank (sheet)

6. Incremental stamping simulation

6.1 Introduction

6.2 Meshing of the part and tools

6.3 Selecting and configuring the material model

6.4 Setting up the different stages using eZ-Setup

6.5 Review of results

7. Case study: Simulation of processes of interest to attendees

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