Practical Guide to Forming Simulation

By Rakesh Kumar

"Practical Guide to Forming Simulation" is a complete set of guidelines to set up a metal forming simulation in Altair hyperworks and hyperform.
After reading this book, the reader would know the basics of Finite element analysis, metal forming simulation.
The detailed explanation of terminologies used in the metal forming simulation set up and the method of one step and incrimental simulation are explained.
After reading this book you will be able to set up the forming simulation at your own and view the results thereafter.
Benefits of using metal forming simulation are quick manufacturing feasibility, accurate blank size calculation, FLD, thinning, wrinkles, cracks before die try out.

• Language: English
• Publisher: Rakesh Kumar
• Release date: Jun 21, 2022
• ISBN: 9781005940904

Rakesh Kumar

I am a graduate Engineer with Masters in Business having 16 years of experience in leading manufacturing industries in India with core R&D design/development profile. I am granted with 3 design patents and 1 utility patent (published), 6 utility patents are applied (yet to be published).As an Author of the book “Practical guide to forming simulation”, I have tried to present the practical solution to metal forming problems via. Computer simulation, which is often called virtual try out. The book comes with theory and practical detailed tutorial, which makes it a job ready program (with some practice).Author is running his own website, kindly visithttps://sharmarakesh.inTo make the learning more interactive, Author has provided the video tutorials along with the 3D cad models for later on practice, on his website.As an Author, i am commited to provide the value against your money.

Book preview

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Practical guide to forming simulation

RAKESH KUMAR

Copyright © 2021 Rakesh kumar

ISBN:9781005940904

All rights reserved. No portion of this book may be reproduced in any form without permission from the publisher, except as permitted by U.S. copyright law.

 For permissions contact:

Rakesh kumar

[e-mail]

[phone]

DEDICATION

This book is dedicated to my wife, Mrs. Rakhi Sharda, who supported and motivated me, while working on this book.

The idea to start the book grew up after reading the book Rich dad poor dad’’ and A millionaire fastlane by MJ D.Marco’’

These both writers generate the spark in me to do some extraordinary, as a result of which this book "Practical Guide to Forming simulation’’ is here for you.

This is not any copy paste book, but a totally new concept. After the name of the book, Same practical things I am preaching, what I am practicing. All the examples of components are taken from the practical real life and you would not find any missing paradox of practice, what other author’s are doing. I am committed to provide the value against your money, to support an interactive learning, I have added video tutorials on my website ‘’sharmarakesh.in’’.

By writing this book I have tried to take the steering of my life in my control.

CONTENTS

ACKNOWLEDGMENTS

1. AN INTRODUCTION TO FINITE ELEMENT ANALYSIS (FEA)

2. FORMING LIMIT DIAGRAM (FLD)

3. ONE STEP FORMING ANALYSIS

4. INCREMENTAL ANALYSIS FOR MULTISTAGE METAL FORMING

5.POST PROCESSING

6.INCREMENTAL FORMING SIMULATION SET UP FOR DRAW-1 PROCESS

7.INCREMENTAL FORMING SIMULATION SET UP FOR DRAW-2 PROCESS

8. CALCULATE THE DRAW FORCE

9. SPRINGBACK ANALYSIS

10. GEOMETRY CLEANUP

11. GRAVITY ANALYSIS

12. MESHING BASICS

13. DIE FACE DEVELOPMENT

ACKNOWLEDGMENTS

The world is a better place thanks to people who want to develop and lead others. What make it even better are people who share the gift of their time to mentor future leaders. Thank you to everyone who strives to grow and help others grow. It is the paperback version of the book Practical guide to Forming simulation

To all the individuals I have had the opportunity to lead, be led by, or watch their leadership from a far, I want to say thank you for being the inspiration and foundation for The Leadership Manifesto.

Without the experiences and support from my peers and team at organization where I had worked, this book would not exist. You have given me the opportunity to lead a great group of individuals—to be a leader of great leaders is a blessed place to be. Thank you to Covid pandemic situation, which keeps me apart from regular routing and to spare some time for writing and flare up my hidden talent of writing

Having an idea and turning it into a book is as hard as it sounds. The experience is both internally challenging and rewarding. I especially want to thank tomy wife that helped make this happen. Complete thanks to all my seniors, colleagues and employers, to provide me the leading opportunity during journey of my career. Thank you for being a leader I trust, honor, and respect. I will always welcome the chance to represent you.

1. An introduction to Finite element analysis (FEA)

Finite element analysis (FEA) is the use of calculations, models and simulations to predict and understand how an object might behave under various physical conditions. Engineers use FEA to find vulnerabilities in their design prototypes.

FEA uses the finite element method (FEM), a numerical technique that cuts the structure of an object into several pieces, or elements, and then reconnects the elements at points called nodes. The FEM creates a set of algebraic equations which engineers, developers and other designers can use to perform finite element analysis.

Frequently, the physical experiences of a product -- such as its structural or fluid behaviour and thermal transport -- are described using partial differential equations (PDEs). Finite element analysis emerged as a way for computers to solve both linear and nonlinear PDEs. However, it is important to note that FEA only provides an approximate solution; it is a numerical approach to finding the real results of partial differential equations.

Using finite element analysis can reduce the number of physical prototypes created and experiments performed while also optimizing all components during the design phase. Finite element analysis software emerged in the 1970s with programs such as Abaqus, Adina and Ansys. Now, it is common to find virtual testing and design optimization integrated into the product development cycle to improve the product quality and reduce the time it takes to enter the market.

Finite element analysis (FEA) is the process of simulating the behavior of a part or assembly under given conditions so that it can be assessed using the finite element method (FEM). FEA is used by engineers to help simulate physical phenomena and thereby reduce the need for physical prototypes, while allowing for the optimization of components as part of the design process of a project.

FEA uses mathematical models to understand and quantify the effects of real-world conditions on a part or assembly. These simulations, which are conducted via specialised software, allow engineers to locate potential problems in a design, including areas of tension and weak spots.

With the use of mathematics, it is possible to understand and quantify structural or fluid behaviour, wave propagation, thermal transport and other phenomena.

Most of the processes can be described using partial differential equations (PDEs), but these complex equations need to be solved in order for parameters such as stress and strain rates to be estimated. FEA allows for an approximate solution to these problems.

FEA is the basis of modern software simulation software, with the results usually shown on a computer-generated color scale.

While some theories state that FEA has its roots in the 16th century work of Euler, the earliest mathematical papers directly detailing the technique date