GENESIS Structural Analysis

and Optimization for Press Die

2014 VR&D User Conference @ Monterey

Takeshi Kobiki
DISQUARE Corporation
 Agenda

1. Introduction
2. Today’s Theme
3. Application of GENESIS to Production Engineering
4. About Practical Use
5. Conclusion

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 DISQUARE Corporation
Established : 2007(Spin-off from DAIZO Corp.)
President : Tadashi Matsuo
Common Stock : \410 million
Stock Holder : DAIZO (100%)
Employees : 150(as of Apr. 2014)
Offices : Tokyo, Osaka, Fukuoka

Oshima Shipbuilding
(Oshima, Nagasaki)

Tokyo Head Office

(Shibuya-ku, Tokyo)

Osaka Office
(Minato-ku, Osaka)
Osaka Shipbuilding
(Minato-ku, Osaka)
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 DISQUARE Skills for Manufacturing Industry
Design and Manufacturing Process
Product Product
Conceptual / Initial / Detail Design Maintenance
Engineering Control
Market Research ERP ・Accounting Management
Sales Making Strategy Digital Engineering ・Sales Management
・Production Management
CAE
・Styling ・Purchase ・Logistics
・3D-Modeling ・Structural Analysis ・After Services
Facility management
R&D ・Digital Mock up ・Motion Analysis
Facility management
・Knowledge Base ・CFD
EDII Maintain Planning
Department

・Design Optimization
Systems Engineering
Electronic Orders
Purchasing ・Requirement Management Exchange CAD Data
・ISO26262/DO172B <Experience in 3D-CAD and CAE>
- Became IBM Partner in 1986
3D Data Usage DigitalCAD/CAM/CAE
- has deployed Factory with mainly CATIA
・Assembly -Manual
Became VR&D Distributor in 2006
・Sales Materials ・Process StudySMS and VisualDOC
Manufacturing - Is supporting Genesis,
・Human Work Simulation
・3D Viewer - Users in heavy industry, electronics, auto OEM and its supplier
・Factory Simulation

Quality
Assurance
Product Data Management
・Project Management
・Product Data Management
・System Security
・Bill of Materials 4
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 Today’s Theme
 Application of GENESIS to product engineering
=> Structural Analysis and Design for Press Die
Sheet Metal Forming Plastic Molding

WELDING

ASTOM R&D has own software products for product engineering

http://www.astom.co.jp/
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 Today’s Theme
 Application of GENESIS to Press Die Design

Demand on lighter structure of products using sheet metal

=>Adoption of high-tensile steel plate

Needs stiffer die

=>Uses GENESIS structural analysis and design

Proposal Solution
=>Will be possible to use existing press equipment

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 Issue about Using High-tensile Steel Plate
 Spring back of High-tensile steel plate is larger.
High Tensile Steel
■ After Spring Back

Large
■ Before Spring Back
980MPa

Bending Deformation

Spring Back
780MPa

590MPa

440MPa

Small
Torsional Deformation
Low Tensile Strength High

Improvement of prediction accuracy of spring back

is important
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 Issue about Prediction for Die Deflection
 Larger die has deflection
 In case of high tensile steel plate, stronger reaction
forces of sheet metal pushes dies
 Sheet metal forming analysis
- Assumption that Dies are rigid body
- Assumption that Dies uniformly contacts
sheet metal
Difference：Stiffness of Die
 Actual press forming
- Dies occurs elastic deformation
- Dies non-uniformly contacts sheet metal
=>Cannot ignore Reaction forces from sheet metal

Needs structural analysis of elastic deformation of dies with

considering of reaction forces from sheet metal
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 Solution Approach
 Minimize Die’s deflection by Genesis Structural Analysis/Design

Sheet Metal Forming Analysis

(ASU/P-form)

Sheet Forming Simulation

Reaction Forces from Sheet Metal

Structural Analysis/Design
Load Condition (GENESIS)

Elastic Deformation of Dies

Evaluate Deflection
Structural Analysis
Modify Geometry Model
(CATIA)

Modify Geometry
Evaluate Spring Back
(ASU/P-form)
Evaluate Spring Back

Stiffened die makes possible to use existing press equipment.

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 Target: Reduction of Iteration numbers of die modification
 For Super High tensile steel plate(>980MPa) ;
Reduction will be over 50% after 2017
Shorten Delivery

Cost Reduction
Die Production Die Production

3-8 times 1-3 times

Die Modification Die Structural Die Modification

Optimization

Physical Test Physical Test

Evaluation Evaluation

2013 After 2017

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 Requirement for Practical Use
 Die Analysis/Optimization :Large FEM Problem
Whole of dies have Large Dimension.
Assembly Assembly Model Forming surfaces have complex shape
Parts A lot of Meshes

Body Contact Large FEM Problem

Non-Linear
Contact Analysis

Performance Speed

Cloud

Many Core

Work Station
Part

Linear Analysis Non Linear Analysis

Require the environment for handling large FEM Problem
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 Thinking about SMP Performance
 SMP performances are like Baseline when threads is changed.
=> Performances are not grow when threads number is over 4.

 Observed the effect of memory bandwidth by adding memory.

=>Very simple test however we got 12% of improvement (8thread).
OS：Cent OS 6.5 64bit
120%
CPU： Intel X5675 @3.07GHz×2 12Cores
ELAPSE TIME(Normalization)

100%
Baseline
Add 4GB*2Slot
80%

60%

Improvement;
40%
12% at 8 threads
20%

0%
1 2 4 6 8
Threads

Would like to try virtual technology that extends available

memory.
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 Conclusion

• Described an innovative design process for press die using

Genesis and ASTOM/P-form.
• Continues to research in order to satisfy target of 2017.

• Also described simple test for improvement of performance.

• It showed bandwidth is effective.

• Would like to try virtual technology that extends available memory.

• Would like to report to VR&D and discuss it.

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 Special thanks to;
Masakatsu Tsuneki, ASTOM R&D.
Kazuhiro Kooriyama, Automotive Design Solution,Inc.
Toshihiro Ueda, DISQUARE, Corp.

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 Thank You.
DISQUARE Corp.
www.di-square .co.jp

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