A Case Study of

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A Case Study of Die validation of fuel tank
using HyperForm 7.0
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Component
250 mm
350 mm
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Material Properties

• The material grade specified for this fuel tank
  is IFCS
• Material Properties specified by raw material
  supplier.
• Youngs Modulus, E 215000 MPa
• Poisson's ratio, nu 0.26
• Yield Stress, s 136MPa
• Strain Hardening index, n 0.21
• Anisotropy ratio, rbar 2.31
• Strength coefficient, K 12603 MPa

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Stages in simulation
Component
Feasibility Study
Die Face Design
Blank Optimizer
Virtual Tryout
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Manufacturing Feasibility Study

• Mid surface Extracted

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Blank developed
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Blank profile ( after adding Trimming allowance)
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Die Face
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Virtual Tryout and Blank optimization

• Tool build
• Process parameters specification
• Tool Motion
• Tool Load
• Draw bead location
• Draw bead parameters
• Lubrication
• Blank Optimization

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Tool Build
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Iteration 01

• Process parameters
• Blank Holding Force 40 Ton
• Friction 0.125
• Draw beads As per the table (next slide)
• Blank shape

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Draw beads ( Iteration 01)
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Formability plot
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Next 10 iterations
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Morphing Die Entry Radii locally
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Morphing Die Entry Radii locally
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Draw beads ( Iteration 02)
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Formability plot
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Thinning plot
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Finished Part
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Our vision towards CAE..
1. To cover all forthcoming developments
existing products through CAD and CAE. 2.
Improve upon accuracy level of analysis. 3.
Cover other applications of analysis as well like
PRODUCT OPTIMIZATION.
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Thank You.