11-15 September 2017
Congress Graz, Austria
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Contribution Oral Presentation

Congress Graz, Austria - Room B
Numerical analysis and simulation

Virtual Hedging of Added Value for incremental formed parts


  • Dr. Ingo NEUBAUER

Primary authors


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There is still an unbroken trend towards higher specifications and performance measures of metallic components and assemblies, no matter how they are processed.There are two major trends forcing engineers from all relevant disciplines–to continuously reach and exceed known limits of existing approaches.The lightweight idea has been establishing as an everyday business task since the last five to ten years but is still challenging engineers. Locally defined properties within given boundaries need to be guaranteed at the end of multiple stage process chains.This requires deeper insight of the interactions between process conditions, material processing and related impacts on changing properties over all measurable length-scales.This calls for new approaches and a change of mindsets from “design-oriented” thinking towards “designed as manufactured”.Additionally modern industries are dealing more and more with “Industry 4.0”.Modern engineering simulation tools play an important role in this process.They enable physical experiments to be replaced by virtual experiments.In addition to significant cost savings, this allow for faster SOP times and will make production of prototypes increasingly obsolete.Doubtless, the complete process chain has to be considered when aiming to predict final properties of the product.Finally, customers are not buying products but performances. In addition, product performances or life times are determined through their properties.Due to get deeper insights of properties and their evolution over a processing cycle detailed knowledge of the process kinematics is required.Often the process kinematics is based on “self-controlled” kinematics-numerous measured values are taken to adjust the process to control product quality and properties dynamically.The same algorithms needs to be implemented into the virtual tools due to model the process output in a reasonable manner. When doing so it must be guaranteed at the same time, that the measured values can be calculated accordingly.Realistic representation of the right parameters with appropriate accuracy levels is a key to reach this goal.Since the process-chains become more complex sophisticated controls alone will not guarantee desired process output.Rather the first initial process and parameter set-up contributes to a robust and stable process situation.One of the classics of simulation tools in this context is the virtual validation of assumed set-up variations.During processing the material undergoes elevated temperatures and work hardening which determine and trigger evolution of the micro-structure.Physical interrelations can be arbitrary complex in this case.The contribution will demonstrate a fully coupled solution to connect machine controls with a virtual simulation platform–exchange information between the different worlds-and finally supports engineering and process planning in developing initial process layout.