Automotive汽车行业:
The Challenges挑战…
How to cope with new
safety regulations, while
reducing weight?如何既减
重，又适应新的安全法规？
How to further reduce the
modules development costs,
and control the supply chain?
如何继续降低研发和制造成本，
如何控制供应链？
How to anticipate the
impact of new materials
and processes, without
going back to testing?如
何不测试就能预估新材料
和工艺的影响?
How to further optimize
the modules assembly
process?如何进一步优化
部件装配成本？
How to cope with new
environmental
regulations, while
increasing comfort?如
何提高舒适性的同时，符
合环境排放法规？
www.twyggy.net
How to cope with new
customers’ requests, in
both developed and
emerging countries?如
何同时满足发达国家和新
兴国家消费者的需求？
How to ensure the full
vehicle performance while
reducing the time-tomarket?如何既缩短研发周
期，又能保证整车的性能。
Copyright © ESI Group, 2012. All rights reserved.
1
Sheet Metal Forming钣金工艺:
The challenges挑战…
How to reduce
production cost ?
如何降低制造成本
How to reduce weight ?
如何减重
http://boronextrication.com/2011/08/2012-audi-a6-body-structure/
How to reduce lead time of
new parts development ?
如何缩短新零件研发周期？
How to keep assembly
possibilities after stamping
with new materials ?
如何保证新材料成形后的装配
进度？
How to keep performances
capabilities after stamping
with new materials ?
如何保证采用新材料后
整车的性能？
Copyright © ESI Group, 2012. All rights reserved.
2
Requirement for Body-in-white
白车身的需求
Light Weight
更轻
Conflicting
requirements相矛盾
Stronger & Stiffer
Higher Energy Absorption
更坚固，更吸能
Solution方案
Ultra High Strength Steel高强度钢
Mild Steel
Bad Formability
成形性差
Large Springback
回弹大
590TS
980TS
Better Solution ?!?!?更好的方案
Hotforming热成形
Copyright © ESI Group, 2012. All rights reserved.
Which parts suitable for hotforming?
哪些部件适用热成形？
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4
VIRTUAL PROTOTYPING
in Press Hardening
材料成形硬化中的虚拟样机
Dr. Martin Skrikerud
Bahia Dahmena
Caroline Borot
Wang Wei
Copyright © ESI Group, 2012. All rights reserved.
5
This is the Job to be Done
“Virtual Prototyping means reducing tests and
physical prototypes with virtual test and prototypes.
This saves the cost for the physical try-out. Also
the time it takes to do the try-out is eliminated”
虚拟样机是指运用虚拟实验和原型来减少物理实验
和物理原型。这样成本以及实验时间大大减少。
The mandatory condition is the ability to deliver results good enough to
reliably replace the physical tests, in a time frame significantly shorter than
physical try-out would be
按照强制标准的虚拟样机使得仿真结果足以可靠地替代物理实验，
其耗费时间明显小于后者
Copyright © ESI Group, 2012. All rights reserved.
6
ESI around the world
ESI全球
More than 30 countries
Paris, France
Eschborn, Germany
15 subsidiaries子公司
Farmington Hills, MI & San Diego, CA, USA
850 people雇员
Bangalore, India
Beijing, China Tokyo, Japan
Copyright © ESI Group, 2012. All rights reserved.
7
39 years of ESI !
ESI已走过39年
1973 Company creation: ESI
1973年公司创立
Iraj Farhooman,
PhD UC Berkeley
1941-1981
Alain de Rouvray,
PhD UC Berkeley
Jacques Dubois,
PhD UC Berkeley
Eberhard Haug,
PhD UC Berkeley
Copyright © ESI Group, 2012. All rights reserved.
Let‘s go back in time: VW Polo Crash
Test, April 16, 1984
1984年大众Polo车碰撞测试
Copyright © ESI Group, 2012. All rights reserved.
First VW Polo Crash Simulation
Polo第一次碰撞仿真模型
Copyright © ESI Group, 2009.
2012. All rights reserved.
Today今天
Copyright © ESI Group, 2009.
2012. All rights reserved.
11
ESI trade solutions
ESI全系列解决方案
Virtual Environment
虚拟环境
Enabled by
a common
Platform
集成平台
Virtual Manufacturing
虚拟制造
Virtual Performance
虚拟样机
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12
All of Virtual Manufacturing is used for
the Hotforming simulation
热成形包容了VM的全部模块
Copyright © ESI Group, 2012. All rights reserved.
13
From AP&T presentation 2 years ago
2年前AP&T演示
Effects of different clearance
不同热间隙的差别
Effects of different contact pressure
不同接触力的差别
Effects of different cooling
不同内浇道的差别
Source: AP&T
Copyright © ESI Group, 2012. All rights reserved.
Sample案例:接触力的影响
Effect of contact pressure
Effects of different contact pressure
So let’s see the
difference between:
1000 kN
3000 kN
5000 kN
Press force
图片给出了三组压机吨位
的冷却效果图。
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15
10s quenching, 1000 kN press force
淬火10秒，压机吨位100吨
Min. Martensite content: 73.7 %
马氏体最小组分为73.7%
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16
10s quenching, 3000 kN press force
淬火10秒，压机吨位300吨
Min. Martensite content: 86.3 %
马氏体最小组分为86.3%
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17
10s quenching, 5000 kN press force
淬火10秒，压机吨位500吨
Min. Martensite content: 91.7 %
马氏体最小组分为91.7%
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18
Conclusion press force
压机吨位的结论
If the objective is 10s quenching time:
如果淬火目标时间为10秒：
1000 kN press force: min martensite: 73.7 %
3000 kN press force: min martensite: 86.3 %
5000 kN press force: min martensite: 91.7 %
Conclusion结论:


Increase press force, or提高压机吨位，或者
Increase quenching time延长淬火时间。
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19
Heating / cooling加热/冷却…
Blank has to be heated to ~900 degrees 板料加热到900度
Then speed feeder into press然后快速传送到压机
Temperature drop app. 20 degrees / sec每秒冷却20度
Test with different transfer times, giving blank temp of:
750 degrees C
800 degrees C
850 degrees C
(all with 3000 kN press force and 10s quenching)
按不同的传送时间，进行三组测试，
板料的初始温度不同；都是300吨位压机，10秒淬火。
Copyright © ESI Group, 2012. All rights reserved.
20
Before quenching (end of forming)
在淬火之前，成形结束时
Even with 750 degrees blank temp, no martensite phase
fraction即使板料温度为750度，也没用马氏体组分。
Copyright © ESI Group, 2012. All rights reserved.
21
Blank temperature 750 degrees C
板料淬火初始温度750度
Min. Martensite content: 86.3 %
最小马氏体组分：86.3 %
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22
Blank temperature 800 degrees C
板料淬火初始温度800度
Min. Martensite content: 76.1 %
最小马氏体组分：76.1 %
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23
Blank temperature 850 degrees C
板料淬火初始温度850度
Min. Martensite content: 45.7 %
最小马氏体组分：45.7 %
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24
Conclusion blank temperature
板料温度的结论
If the objective is 10s quenching time:
设定淬火时间10秒
750 degrees C: min martensite: 86.3 %
800 degrees C : min martensite: 76.1 %
850 degrees C : min martensite: 45.7 %
Conclusion结论:


Transfer time oven to press is not critical
从加热炉到压机的传送时间不是关键因素
Copyright © ESI Group, 2012. All rights reserved.
25
Tool temperature
Why cool the tools?
模面温度，为什么要对模具内部进行冷却？
Starting configuration can be assume with tools at 25
degrees C初始温度可设为25度
But if not properly cooled, tool temperature increases
如果冷却不当，模面温度会升高
Test with different tool temperatures of:进行三组测试
25 degrees C
100 degrees C
200 degrees C
(all with 3000 kN press force and 10s quenching, blank
temperature at 750 degrees C)
都是300吨压机，10秒淬火，板料初始温度750度。
Copyright © ESI Group, 2012. All rights reserved.
26
Tool temperature 25 degrees C
模面温度25度
Min. Martensite content: 86.3 %
最小马氏体组分为86.3 %
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27
Tool temperature 100 degrees C
模面温度100度
Min. Martensite content: 81.4 %
最小马氏体组分为81.4 %
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28
Tool temperature 200 degrees C
模面温度200度
Min. Martensite content: 55.0 %
最小马氏体组分为: 55.0 %
Copyright © ESI Group, 2012. All rights reserved.
29
Conclusion tool temperature
模面温度结论
If the objective is 10s quenching time:假定淬火时间10秒
25 degrees C: min martensite: 86.3 %
100 degrees C : min martensite: 81.4 %
200 degrees C : min martensite: 55.0 %
Conclusion结论:



Tool temperature is critical模面的温度是决定因素；
A increase to a tool temperature of 200 degrees means part
performance will definitely fail
如果模面温度达到200度，工件将无法达到样机测试的要求。
Copyright © ESI Group, 2012. All rights reserved.
30
Why is simulation of phase
transformation important?
为什么相变转换的模拟很重要？
In the last case, the difference in thinning between tool
temperature of 25 degrees C and 200 degrees C is
20.1% vs 20.8%:刚才的工况，模面25度和200度其减
薄率分别是20.1%，20.8%
Tool temp of 25 degrees C gives
Max thinning of 20.1%
Tool temp of 200 degrees C gives
Max thinning of 20.8%
Copyright © ESI Group, 2012. All rights reserved.
31
Sample part案例:
Panel Dash – courtesy of AP&T授权
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32
Tools meshed and joined with cooling
channels带内浇道模具的网格划分与装配
1 - Read CAD
4 – 3D Layer Mesh
2 – Automatic volume detection and repair
3 – CAD Assembly
Copyright © ESI Group, 2012. All rights reserved.
33
3D tools ready for simulation
3维实体模具
Courtesy of:
AP&T授权
3D tools with
cooling channels
~3 million elements
带内浇道的实体模具，
300万单元
Copyright © ESI Group, 2012. All rights reserved.
34
3D cooling simulation:
mapping of blank onto 3D tools
模具实体模拟:从板料映射到3维模具
Temperature at the
end of forming成形结束时温度
Courtesy of:
AP&T授权
Temperature at the
end of quenching
淬火结束时温度
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35
Different cycle times, different tool temperatures
不同的循环周期，导致模具温度不同
Cycle times is a crucial parameter in hotforming循环周期
至关重要
Besides determining the martensite content in the blank at
the end of forming, it also is important for the tool
temperature除了决定马氏体组分，它还影响模具温度
If cycle time is wrong, tool temperature increases如果循环
周期不恰当，模面的温度将升高
Test with different cycles of:测试不同循环周期
5s quenching, 5s open 5秒淬火，5秒开模取零件
7.5s quenching, 5s open 7.5秒淬火，5秒开模取零件
10s quenching, 5s open 10秒淬火，5秒开模取零件
(all with 3000 kN press force and blank temperature at
750 degrees C)
Copyright © ESI Group, 2012. All rights reserved.
36
5s quenching, 5 s open,4 cycles
5秒淬火，5秒开模，4个循环后
Max. Tool temperature: 96.1 ºC
模面最高温度：96.1 ºC
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37
7.5s quenching, 5 s open,4 cycles
7.5秒淬火，5秒开模，4个循环后
Max. Tool temperature: 115 ºC
最高模面温度：115 ºC
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38
10s quenching, 5 s open,4 cycles
10秒淬火，5秒开模，4个循环后
Max. Tool temperature: 225 ºC
最高模面温度：225 ºC
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39
Conclusion cycle times
循环周期的结论
Max tool temperature with these cycles:
模面最高温度分别是：
5s quenching, 5s open: 96.1 ºC
7.5s quenching, 5s open: 115 ºC
10s quenching, 5s open: 225 ºC
The ratio closed / open tools is the determining for the tool
temperature evolution 模具开/闭的时间比例决定了模面的温
升
If martensite is reached in a short cycle time, tools are ok with that 如果
在较短循环时间能得到马氏体，模具的温度能满足需求。
Adding some time to the “open time” will decrease the tool temperature
significantly适当延长模具开模时间，能有效降低模面温度。
Copyright © ESI Group, 2012. All rights reserved.
40
Possible hot spot detection
模具内可能需要的温度测点
Cooling channel redesign needed?
内浇道需要重新设计？
Problem area
出问题区域
Courtesy of:
AP&T授权
Copyright © ESI Group, 2012. All rights reserved.
41
How accurate is it?
精度如何？
Courtesy of AP&T授权
Location测点 Difference偏差
1
-4,0%
2
-0,3%
3
-0,8%
4
2,4%
5
-3,4%
6
-2,3%
7
-2,3%
8
0,6%
9
-2,1%
10
-0,6%
11
2,0%
12
-0,4%
13
3,3%
14
-2,2%
15
0,7%
16
0,0%
17
-0,6%
18
1,1%
19
-0,5%
20
3,2%
21
-0,1%
Copyright © ESI Group, 2012. All rights reserved.
42
WHAT’S NEW IN V2012?
PAM-STAMP 2012新功能？
Copyright © ESI Group, 2012. All rights reserved.
43
Hotforming V2012热成形:
Improved usability提高易用性
Cooling system analysis
PamStamp 2G v2012:
Simplified set-up for cooling
channels内浇道设置更简便
Automatic selection
自动选取
Copyright © ESI Group, 2012. All rights reserved.
44
Hotforming V2012热成形:
Time reduction仿真时间缩短
Cooling system analysis
Improvement of thermal mass
scaling and automatic calculation:
自动计算热质量缩放因子，
Significant Reduction of CPU time
for cooling channel calculation
显著缩短内浇道计算的CPU时间
PamStamp 2G v2012:
CPU Time reduction
Copyright © ESI Group, 2012. All rights reserved.
45
Hotforming V2012热成形:摩擦系数曲线
Temperature depending friction
Source: AP&T
Formability &
process definition
PamStamp 2G v2012:
Friction dependency on
temperature摩擦系数可随温度变化
Copyright © ESI Group, 2012. All rights reserved.
46
Hotforming V2012热成形:
Cooling rate冷却速率
Formability &
process definition
PamStamp 2G v2012:
cooling rate during quenching
能计算淬火时冷却速率
Copyright © ESI Group, 2012. All rights reserved.
47
Hotforming V2012热成形:
Hardness value (Hv)硬化值
Formability &
process definition
PamStamp 2G v2012:
Hardness prediction by chemical
components, phase fraction and cooling rate
通过化学成分、相组分及冷却速率分析硬化值
Copyright © ESI Group, 2012. All rights reserved.
48
Increasing trend趋势:拼焊板越来越多
Tailored and patchwork blanks
Source: ArcelorMittal
阿赛洛米塔尔
Source: CPF – OHIO state University
俄亥俄州立大学
Copyright © ESI Group, 2012. All rights reserved.
49
Hotforming V2012:拼焊板的前处理
Dedicated tailored blank preprocessing
PamStamp 2G v2012:
For Hotforming and Cold forming
Tailored and Patchwork Blanks
Blank creation
 Simplified set-up设置简单
 Easy iteration on tailored lines快速生成焊缝线
 Die Compensation for Tailored Blanks拼焊板回弹补偿
 3D curves in post-processing后处理3D曲线
Tool creation
创建焊缝线
Copyright © ESI Group, 2012. All rights reserved.
Hotforming V2012:拼焊板的后处理
Dedicated tailored blank postprocessing
Initial temp blank板料温度: 920º
Initial temp tool left左模面: 70º
Initial temp tool right右模面:300º
Formability &
process definition
PamStamp 2G v2012:
Tailored & patchwork
Hotforming blank拼焊板热成形
Proportion of
Martensitic phase
马氏体组分
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51
New in Hotforming V2012新增功能:
Aluminium warm forming铝板温间成形
Source: KOBE STEEL,LTD – PUCA
2010神户制铁，2010年会
PamStamp 2G v2012:
Aluminium warm forming with
 Thermal exchanges热交换
Strain annealing退火消除应变
 Friction dependant on temperature摩擦系
数随温度变化
增加本构Barlat’s Yld2000-2D additionally to
the already included material models
Copyright © ESI Group, 2012. All rights reserved.
52
WE ARE ALSO WORKING ON…
新版本还具备以下功能
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53
Body Engineering in Automotive
General Overview车身工艺流程总览
Copyright © ESI Group, 2012. All rights reserved.
One Goal – Managing Assembly Tolerances Including
Effects of Component Fabrication and Advanced Materials
目标---控制装配容差，考虑零件制造的影响及先进的材料
Die Face
Design Based
on Geometry
Forming
Spring
back
Restrike
Spring
back
Flanging
Spring
back
Hemming
Spring
back
Assembly
www.carbodydesign.com
Based on one model and one platform
以单个模型、单一平台为基础
Copyright © ESI Group, 2012. All rights reserved.
55
Model Preparation
模型前处理
Spot Weld
焊点
Contact Area接触区域
Normal to
SW_P1
Normal to
SW_P2
Angle to
Be checked
GAP
Copyright © ESI Group, 2012. All rights reserved.
56
Sheet Metal Forming – Spot Welding
Assembly钣金工艺-电焊-装配
Stamping
Spot-Weld Assembly
Assembly sequence
Compensation
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57
Summary
总结
Virtual prototyping helps saving real prototypes in a shorter
time at a lower cost虚拟样机能缩短周期，降低成本
Parameter studies & influence factors can easily be
determined using Virtual Prototyping借助虚拟样机，能方便
地研究参数及其影响权重。
New functions for V2012 such as hardness, speed-up and
improved usability新版本提供了硬化值分析、加快了求解速
度、提高了易用性
Every part manufactured is part of a bigger body, which
needs to be assembled每个单独的零件都是车身的一部
分，必须要考虑对装配的影响。
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58
Thank you for your attention!
联系方式
ESI(中国)工程部
王玮
TEL : 010-6554-4909
E-Mail: [email protected]
Copyright © ESI Group, 2012. All rights reserved.