Research And Development Of Pre-process System For Complete Process Simulation Of Sheet Forming Based On Catia V5

The application of FEM technology in numerical simulation of metal sheet forming raises the productivity of automobile panel and promotes development of auto industry. But the current software of sheet forming analysis is always applied to simulate the single process, and needs data transition between CAD and CAE platform which trends to cause the loss of model data, increase the time of the pre-processor operation and lower the result precision of simulation. So, in order to meet the needs of flow line and multi-process production, raise the productivity and reduce costs, the development of sheet forming CAE system integrated seamlessly with CAD platform is necessary and significant to automobile production and the whole auto industry.This research is one part of NSF program named: "The Independent Research of High-speed Simulation and Optimal Process Design aiming at the Formability of Automobile Panel" (NO.50575080) and National 863 program named: "The Formability and Optimal Process Design Based on the Simulation of Automobile Parts"(NO. 2006AA04Z140). With the CAA secondary development technology, the project completed the design and the development of complete stamping process CAE pre-processor system based on CATIA V5.In this paper, the author describes the trend of CAD/CAE integration, introduces the environment and tools of CAA secondary development, and discusses the frame and design philosophy of the system. Through analysis of the special software of simulation of sheet forming, the overall structure and workflow are determined. According to the factual production, the system takes full advantage of CAD with characteristics of modular operation and node-type management. Meanwhile, the key technology such as the virtual assembly, parameterized associated design, tool mesh tessellation, attribute storage and so on has been solved. Finally, all functions of the system have been implemented.The simulation of sheet forming system based on CATIA V5 carries out the seamless integration between CAD and CAE. The system considers the influence of friction, holding force, draw-bead and other actual process conditions, can simulate drawing, trimming, flanging process, and evaluate the spring-back trend. Simulation to typical automobile panels has reflected the parameterized, simplified and modular characteristics of the system and proved its accuracy and stability.