Highly Accurate Finite Element Simulation for Sheet Metal Forming

Indeed is a sheet metal forming simulation software that combines ease of use with high quality simulation. The software covers the entire range of sheet metal forming processes and allows for the accurate simulation of complex multi-stage sheet metal forming processes. It also provides precise prediction of springback and reliable results of press forces and tool stresses. Indeed reduces the number of costly trial-and-error-loops drastically and guarantees that process development targets can be achieved quickly and in a cost-effective way. Indeed can easily be customized to individual needs, thus offering made-to-measure solutions for a customer's special requirements.

 

Increase Process Quality

Speeding up Innovation - Reducing Costs

 

Numerical forming simulation is indispensable today for reliably predicting the formability of metal and plastic parts as well as for shortening development times and therefore cutting costs.

 

Indeed offers a unique range of innovative high-precision calculation models for the simulation of forming processes, which are continually updated and adapted to technological innovations in close cooperation with users. The intensive exchange of experience among users, technology partners, material manufactures and universities guarantees that Indeed will continue to meet future demands.

 

In connection with experimentally validated material laws, problems encountered in daily practice can be quickly described and a highly exact solution obtained.

 

The newly developed, process-oriented, intuitively operated graphical user interface OpenForm ensures an extremely easy data set-up and quick analysis of results. By means of OpenForm even inexperienced users now have access to complex high-end forming simulation.

 

Indeed is based on the incremental finite element method (FEM). This means that the balance between inner and outer loads is determined in each incremental load step throughout the whole calculation. Therefore, the springback of the formed part can accurately be determined with only one unloading step due to the elastic component in the material law.

 

A comparison between the simulation results and the specifications of the part to be manufactured allows the method planner and toolmaker to carry out and examine modifications on the virtual model instead of on the tool itself.

 

Allowance for draw beads, blank holder segmentations and operational sequences from cutting to seaming is just as much a part of the capabilities of Indeed as the incorporation of additional tools and tailored blanks into the calculation.

 

Indeed has been optimized for the simulation of deep drawing processes as a result of a close cooperation with German automobile companies. However, its general implementation also makes it readily adaptable to user-specific forming processes. Today, besides its application in the simulation of complex multi-stage deep drawing processes, Indeed is used in a great many different areas, such as

  • crash forming
  • hydro-mechanical forming
  • tube bending
  • tailored rolled blanks
  • rolling
  • flanging
  • joining

 

Finite Elements

 

Indeed offers a variety of elements for the simulation of forming processes. Depending on the stage of the planning, the user can decide whether a quick design solution or a more accurate answer is necessary. The membrane element is highly suitable for design solutions in the optimization process. This element is able to provide valuable predictions about the feasibility of a planned process in a short period of time. It is preferably used in method planning and tool design in the first half of the design process.

 

Highly accurate results allowing reliable conclusions can be obtained with the solid shell element that was specially developed for the deep-drawing process. In addition to excellent bending and membrane characteristics, the element formulation includes the change of thickness as an independent degree of freedom. In contrast to the classical shell element, this allows an efficient description of the friction contact on both sides. A further advantage is that membrane element and the shell solid element work with the same tool description so that models can be easily interchanged.

 

Material Models

 

The successful numerical simulation of metal forming requires realistic material laws for the mechanical description of the materials used. Material laws for different steel and aluminium alloys are available in Indeed. The implemented material models allow modeling of large plastic deformations. The general strain hardening which occurs during the forming process has been validated experimentally by extensive bi-axial tests for various materials. The elastic component in the material law enables the determination of the stress distribution in the thickness direction in connection with the kinematics of the shell element. This makes realistic springback prediction possible.

 

Graphical User Interface

 

Indeed comes along with the graphical user interface OpenForm. The use of OpenForm guarantees that product or tool engineers who do not have first-hand experience with finite element analysis (FEA) can carry out complex and highly precise forming simulations with only a few days of training.

 

Systems Requirements

 

Indeed can be used on all workstations, servers and personal computers that run with either LINUX, UNIX or Windows operating systems. Indeed is highly vectorized and parallelized and users have the option of employing very efficient parallel computers based on current and future standards.
 
Since April 2010 Indeed is certified as IntelClusterReady.

 

 

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Program Versions

Animator4 2.2.3
Generator2 0.1.5
Generator4 1.2.1
Indeed 9.2.5
OpenForm 2.8.1
pam_med 1.1.25