[Case Study] Predicting Defects in Press Forming and Sheet Forging Using CAE Applications

In press die design, the settings for "pilot hole diameter" and "vertical wall height" in burring processes tend to rely on empirical rules and trial-and-error. This is particularly true for high-strength steel sheets (high-tensile), where the risks of cracking and thickness reduction are significant, requiring a considerable amount of time to establish conditions. The plastic processing simulation software "DEFORM" addresses these challenges. 【Identify the "correct answer" with CAE before actual prototyping】 By utilizing DEFORM's "Design of Experiments (DOE)" feature, multiple conditions such as pilot hole diameter and punch shape can be digitally verified all at once for formability. This allows for a quantitative understanding of forming limits and cracking risks, enabling the derivation of optimal processing conditions in a short time. For more details, please refer to the related link.

Are you struggling with the phenomenon where holes, which should ideally be "perfectly round," become distorted in the manufacturing of automotive motor cores and electronic components? Even if we can speculate that mold deflection is the cause, measuring the behavior during processing is difficult. As a result, the current situation often involves repeatedly prototyping based on "intuition and experience," leading to enormous time and cost spent on corrections. In this case study, we used the plastic processing simulation software "DEFORM" to reproduce the phenomenon of hole ovalization. We clarified the mechanisms of distortion that had previously been a black box. - Identifying factors: Quantifying the impact of mold and machine rigidity on precision. - Pre-validation: Simulating the effects of countermeasures before prototyping to reduce rework. For more details, please refer to the related links.

Are you facing such walls when trying to examine complex shape forging processes with CAE? - The computation time is enormous, making it difficult to cycle through PDCA. - Spending several days just to set conditions. - Ultimately, the results do not match the actual machine behavior and cannot be fully utilized. Especially for difficult shapes like two-stage helical gears, the "computation cost barrier" from 360° full model analysis becomes a significant obstacle. In this article, we will reveal the efficient analysis process utilizing "sparse gear segmented model (90°) × DEFORM" practiced by Yamanaka Gokin. First, we will use a fast segmented model to get a preliminary assessment, and then conduct full model verification in the final stage. We will provide a detailed explanation of a method that truly helps in practice, achieving a balance between computation cost and accuracy. For more details, please refer to the related links.