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News Release from: Corus Automotive | Subject: Predictive metal forming modelling technique
Edited by the Manufacturingtalk Editorial
Team on 12 September 2007
Forming to strength model reduces costs
A 'Forming to Strength' predictive modelling technique is helping a vehicle chassis manufacturer to validate the strength of pressed sheet metal sub-assembly components.
International metals company, Corus, has deployed its Forming to Strength (F2S) predictive modelling technique to help TKA Tallent Chassis validate the strength of sub-assembly components It is essential that component manufacturers and car makers understand how steel will perform and behave as it is formed into shape
This article was originally published on Manufacturingtalk on 31 May 2006 at 8.00am (UK)
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Corus has developed a number of modelling techniques that enable customers to include these changes in material properties in crash, fatigue or strength analyses as an integral part of the product development process.
Corus worked with Tallent to validate the F2S technique on a suspension lower control arm, which uses Corus Tenform XF300 and XF400 HSLA (high strength low alloy) steel grades.
Conventional finite element strength modelling does not include changes in the steel properties resulting from the forming process.
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However, the Corus F2S technique takes the formed thickness and material strength from PAM-STAMP forming analysis and uses this as inputs to ABAQUS (finite element software) strength analysis.
Strength tests conducted by Tallent on the lower control arm showed that conventional finite element modelling under-predicts the measured strength by 13%.
However, when using the Corus F2S technique, the accuracy of the prediction was within 1% of the measured strength.
By utilising this new computer aided engineering approach, Corus and its customers are able to work together to reduce lead times and therefore costs during the development process.
Commenting on the benefits to customers of using Corus' specialist analysis techniques, Rene Kieft, manager Product and Technology, Corus Strip Products, said: "Our F2S predictive model is just one of a number of unique analysis simulation tools, which include Forming to Crash (F2C) and Forming to Fatigue (F2F), that we can provide customers to help them maximise the value of the steel Corus supply.
Crucially, by using these CAE tools, customers such as Tallent, can more quickly and more robustly evaluate the potential benefits of introducing new materials to the component production process during the life span of a vehicle without incurring prohibitive cost and time." Dr Adam Towse, analysis supervisor, TKA Tallent Chassis, added: "The ability to introduce new materials is particularly important as there is a growing demand from our OEM customers to use today's modern High Strength and Dual Phase steels in order to meet the on-going need to reduce vehicle weight whilst maintaining performance and strength. Request a free brochure from Corus Automotive ...
Corus' predictive modelling techniques allow us to evaluate new materials in order to successfully introduce these modern steel products to the benefit of our customers.".
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