Improved Finite Element Simulations to Expedite Product Development

Sheet metal parts are increasingly being developed by simulating the deformation process, in order to optimize the development time and improve the design quality. These simulations are often compared with modern optical measuring methods working on the principle of image processing to provide detailed information on 3D surface geometry, deformation as well as strain on formed sheet metal components. Together, the FEA and optical measuring systems play a significant role in the industrial product development cycles.

Evaluation of the material parameters as well as component deformation behavior through optical measuring tools can serve as an important input for simulation calculation, and ensures that the results are more accurate and reliable.

Optical measuring systems often include 3D motion and deformation sensor to determine material properties like Young’s modulus, R-value, n-value as well as forming limit curve. Optical forming analysis systems are also employed to determine the forming distribution of sheet metal components and subsequently optimize the forming processes.

The results obtained through these systems can then be verified with the numerical simulations performed using FEA tools like ANSYS Mechanical. Moreover, the results can also be used to define the material model more accurately for accurate simulation results. This eventually helps increasing the confidence in the simulations and shrinks the product development cycle by delivering-

  • Valuable input parameters to define material model accurately for accurate prediction of material behavior
  • First article inspection (FAI) in order to perform prototype analysis faster
  • Reliable feedback to optimize the simulation and thereby reduce number of iterations
  • Valuable know-how on developing future products with less development time

Hi-Tech Engineering Services has remained a vital partner to deliver accurate sheet metal design support solutions to clients ranging from industrial equipment manufacturers, furniture manufacturers, and architectural metal product manufacturers to manufacturers of kiosks, HVAC ducts and sheet metal enclosures. To ensure that simulation accuracy, we often perform validation and verification of our material models with experimental data, ensuring reliable results for our clients.

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