| 1. |
- Barlo, Alexander, M.Sc. Eng. 1994-, et al.
(författare)
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Creating a Virtual Shadow of the Manufacturing of Automotive Components
- 2024
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Konferensbidrag (refereegranskat)abstract
- Within the automotive industry, there is an increasing demand for a paradigmshift in terms of which materials are used for the manufacturing of the automotive body. Globalclimate goals are forcing a rapid adaption of new, advanced, sustainable material grades suchas the fossil free steels and materials containing higher scrap content. With the introduction ofthese new and untested materials, methods for accounting for variation in material propertiesare needed directly in the press lines.The following study will focus on creating an initial virtual shadow of the manufacturing of aVolvo XC90 inner door panel through the application of Artificial Neural Networks (ANN). Thevirtual shadow differs from the concept of the digital twin by only being a virtual representationof the production line, with training data generated exclusively by numerical simulations, andhaving no automated communication with the physical press line control system. The virtualshadow can be used as an assistance to the press line operators to see how different press linesettings and material parameter variations will impact the quality of the stamped component.The study aims to validate the virtual shadow through accurate predictions of the materialdraw-in measured in the physical press line.
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| 2. |
- Barlo, Alexander, M.Sc. Eng. 1994-, et al.
(författare)
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Determination of Edge Fracture Limit Strain for AHSS in the ISO-16630 Hole Expansion Test
- 2023
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Ingår i: 42ND CONFERENCE OF THE INTERNATIONAL DEEP DRAWING RESEARCH GROUP. - : IOP PUBLISHING LTD.
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Konferensbidrag (refereegranskat)abstract
- With the increased demand for application of sustainable materials and lightweight structures, the sheet metal forming industry is forced to push existing materials to the limits. One area where this is particular difficult is when it comes to assessing the formability limit for sheet edges. For decades, the ISO-16630 Hole Expansion Test (HET) has been the industry standard for expressing the edge formability of sheet metals through the Hole Expansion Ratio (HER). However, in recent years, this test has been criticized for its high scatter in results for repeated experiments. This scatter has been suspected to be caused by the operator-reliant post-processing of the test, or variations in the cutting conditions for the different test specimens. This study investigates the impact of shifting the evaluation point of the test from the through-thickness crack to the onset of surface failure on the reported scatter, as well as performs inverse modeling of the Hole Expansion Test to obtain an edge limit strain value.
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| 3. |
- Barlo, Alexander, M.Sc. Eng. 1994-
(författare)
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Failure Prediction of Complex Load Cases in Sheet Metal Forming : Emphasis on Non-Linear Strain Paths, Stretch-Bending and Edge Effects
- 2023
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- With the increased focus on reducing carbon emissions in today’s society, several industries have to overcome new challenges, where especially the automotive industry is under a lot of scrutiny to deliver improved and more environmentally friendly products. To meet the demands from customers and optimize vehicles aerodynamically, new cars often contain complex body geometries, together with advanced materials that are introduced to reduce the total vehicle weight. With the introduction of the complex body components and advanced materials,one area in the automotive industry that has to overcome these challenges is manufacturing engineering, and in particular the departments working with the sheet metal forming process. In this process complex body component geometries can lead to non-linear strain paths and stretch bending load cases, and newly introduced advanced materials can be prone to exhibit behaviour of edge cracks not observed in conventional sheet metals. This thesis takes it onset in the challenges seen in industry today with predicting failure of the three complex load cases: Non-Linear Strain Paths, Stretch-Bending,and Edge Cracks. Through Finite Element simulation attempts are made to accurately predict failure caused by aforementioned load cases in industrial components or experimental setups in an effort to develop post-processing methods that are applicable to all cases.
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| 4. |
- Barlo, Alexander, M.Sc. Eng. 1994-, et al.
(författare)
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Investigation of a Bending Corrected Forming Limit Surface for Failure Prediction in Sheet Metals
- 2019
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Ingår i: Forming Technology Forum.
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Konferensbidrag (refereegranskat)abstract
- Ensuring process feasibility is a high priority in the automotive industry today. Within theCAE departments concerning the manufacturing of body components, one of the most important areas ofinterest is the accurate prediction of failure in components through Finite Element simulations. This paperinvestigates the possibility of introducing the component curvature as a parameter to improve failureprediction. Bending-under-tension specimens with different radii are used to create a Bending CorrectedForming Limit Surface (BC-FLS), and a test die developed at Volvo Cars, depicting production-like scenariosby exposing an AA6016 aluminium alloy blank to a stretch-bending condition with biaxial pre-stretching, isused to validate the proposed model in the commercial Finite Element code AutoFormTM R8. The findings ofthis paper showed that the proposed BC-FLS approach performed well in the failure prediction of the test diecompared to the already in AutoFormTM R8 implemented max failure approach.
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| 5. |
- Barlo, Alexander, M.Sc. Eng. 1994-, et al.
(författare)
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Investigation of Temperature Impact on Friction Conditions in Running Production of Automotive Body Components
- 2024
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Konferensbidrag (refereegranskat)abstract
- During the running production of automotive body components drifts in theprocess window is seen causing problems with non-conforming parts. Up until now, these driftshave been counter-acted based on the knowledge and experience of the press line operators.This experience-based process control will however become more troublesome in the future asrecycled material grades will undoubtedly present larger in-coil variations in material parametersand effect also the friction conditions from component to component.The following study will present two cases from production of the Volvo XC60. For thetwo cases, the initial simulations made for the components showed a safe part, but duringrunning production failure occurred suspected to be due to temperature effects in the tribologysystem. The study will furthermore present updated simulations considering developing thermaleffects to replicate the failures, as well as present both standard and thermal simulations of theadjustments made in production.
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| 6. |
- Barlo, Alexander, M.Sc. Eng. 1994-, et al.
(författare)
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Proposal of a New Tool for Pre-Straining Operations of Sheet Metals and an Initial Investigation of CR4 Mild Steel Formability
- 2023
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Ingår i: 42ND CONFERENCE OF THE INTERNATIONAL DEEP DRAWING RESEARCH GROUP. - : IOP PUBLISHING LTD.
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Konferensbidrag (refereegranskat)abstract
- With the increased focus on reducing carbon emissions in the automotive industry, more advanced materials are introduced to reduce the vehicle weight, and more complex component geometries are designed to both satisfy customer demands and to optimize the vehicle aerodynamically. With the increase in component complexity, the strain paths produced during the forming operation of car body components often display a highly non-linear behavior which makes the task of failure prediction during the manufacturing feasibility studies more difficult. Therefore, CAE engineers need better capabilities to predict failure induced by strain path nonlinearity. This study proposes a new tool designed for creating bi-linear strain paths, by performing a pre-strain of a sheet large enough to cut out Nakajima specimens to perform the post-straining in any direction. From five pre-straining tests the tool present a stable pre-straining operation with a uniform strain field in a radius of 100 [mm] from the centre, corresponding to the region of interest of a Nakajima specimen. From the five pre-strained samples, different Nakajima specimens are cut transverse and longitudinal to the rolling direction and a failure prediction approach in an alternative, path independent evaluation space was used to predict the onset of necking with promising results.
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| 7. |
- Tuan Pham, Quoc, et al.
(författare)
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An evaluation method for experimental necking detection of automotive sheet metals
- 2023
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Ingår i: 42ND CONFERENCE OF THE INTERNATIONAL DEEP DRAWING RESEARCH GROUP. - : IOP PUBLISHING LTD.
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Konferensbidrag (refereegranskat)abstract
- In sheet metal stamping, the occurrence of strain localization in a deformed sheet is considered a failure. As so, sheet metal's formability is conventionally evaluated using the Forming Limit Diagram (FLD), which separates the principal strain space into safety and unsafety regions by a Forming Limit Curve (FLC). This study presents an evaluation method for detecting strain localization based on Digital Image Correlation (DIC) during the experiment. The commercial DIC software ARAMIS is adopted to monitor the strain-field distribution on the deformed specimen's surface. A detailed analysis of the proposed method is presented considering Nakajima tests conducted for two automotive sheet metals: AA6016 and DP800. The identified FLC based on the proposed method is compared with that of well-established methods such as ISO 12004:2-2008 and time-dependent methods. For both investigated materials, the proposed method presents a lower FLC than the others.
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| 8. |
- Tuan Pham, Quoc, et al.
(författare)
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Modeling the strain localization of shell elements subjected to combined stretch–bend loads : Application on automotive sheet metal stamping simulations
- 2023
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Ingår i: Thin-walled structures. - : Elsevier Ltd. - 0263-8231 .- 1879-3223. ; 188
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Tidskriftsartikel (refereegranskat)abstract
- This study presents a modeling approach for predicting strain localization during sheet metal stamping processes focused on automotive engineering applications. The so-called stretching-to-bending ratio, ρ, is proposed to characterize the loading conditions acting on an element during stamping processes. Then, localized strain or necking strain is suggested to be a function of ρ. Different stretch–bending tests with different tool radii, i.e., R3, R6, R10, and R50 are conducted for two automotive sheet metals, DP800 and AA6010, to identify their forming limits under combined stretch–bend loads. The calibrated necking limit curve of the AA6016 sheet is then employed in AutoForm R10 software to predict the necking and failure of a stamped panel. Agreement with the experimental observation of failure positions of the panel validates the usefulness of the proposed modeling approach in practice.
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