Northwestern University Robert R. McCormick School of Engineering and Applied Science

Advanced Manufacturing Processes Laboratory

A Simplified 2D Model for Predicting Failure in 3D Parts

Our research interest lies in the area of algorithms in the die design and computer simulations in the sheet metal forming process. The intensive global market competition has increasing pressure on industries to shorten their development cycles and to reduce manufacturing costs. One solution would be to develop reliable simulation models to aid product and process design during early development stages. As a key element in automobile industry, sheet metal forming has been numerically simulated using Finite Element Method (FEM). With the rapid development in computer technology and FEM , a complete modeling of 3-D part and its forming process is becoming realistic. However, in many cases, the computation time is still too long to make simulations effective in assisting the design process and therefore, simplified 2D models which can predict material behavior reasonably well are in great demand. Our current work aims to provide a simplified 2D model to predict tearing failure in the corner sections of complicated 3D parts. Completion of this project will enable users to detect failure reasonably well in a matter of seconds compared to typically hours of computation time for a 3D simulation, and therefore, will allow optimization of die and process design in early stage and quick turn-around

This work is sponsored by General Motors Corporation.

Related Publications

  • Yao, H., Kinsey, B. and Cao, J. (1999) "Rapid design or corner restraining force in deep drawn rectangular parts", to appear Inter national Journal of Machine Tools and Manufacture. Abstract Full Paper

  • Yao, H., Kinsey, B. and Cao, J. (1999) "A simplified 2-D model for predicting 3-D corner failure in a square part", 1999 Society of Au tomotive Engineers International Congress & Exposition, paper No. 1999-01-1317, Detroit, MI. Abstract Full Paper