Introduction Pam Stamp (ESI)

 Nearly all sheet metal forming processes can be virtually displayed with Pam Stamp.

 The software is mainly optimized for deep drawing, bending and roll forming processes.
Therefore a choice of pre-defined macros exist to support an efficient treatment and
analysis of the announced “standard processes“. Even the spring back behavior of the
material can be computed.

 An automatic meshing tool (Delta mesh) is additionally included to ensure a proper,

comfortable pre-processing. The software is capable to process and handle all common
mesh formats (ANSYS, NASTRAN, PATRAN ect.).

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It may not be copied, disclosed or used for any purpose without the prior written consent of Tenneco Inc..
 Compare Solver
 Explicit / Implicit Solver (virtual prototyping)
 Multi & single step processes can be displayed by reflecting the real process including toolset,
kinematics and forces.

+ Advantage: precise results / pre-strain of material is respected / ok for validation

– Disadvantage: large effort / geometries of toolset, kinematics and forces of process ≈6h
to be defined / large computation time
Computation time
1. blank 2. Draw_1 2. Draw_2 3. Trimming and calibration (1x op.)

 Inverse Solver (one step)

 By an approximation calculation the formed part is projected on a flat / curved target surface

+ Advantage: small effort / geometries of toolset, kinematics and forces not needed
/ fast determination of blank size possible / applicable for RFQ’s
– Disadvantage: rough result / pre-strain of material is not respected / not ok for validation
≈0,25h
1. part 2. Blank and final shape
Computation time
(complete)

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It may not be copied, disclosed or used for any purpose without the prior written consent of Tenneco Inc..
 Material characteristics
for PAM-STAMP (forming simulation)
 Reliable material data as input for forming simulations have to be determined
by acknowledged experts!
 Sample: 1.4509 (Aperam F18TNb)
Young‘s module :215 MPa
(Poisson number) :0,3
(density) :7,7 kg/dm³
r0 :1,18
r45 :1,04
r90 F F
:2,22 A0

Flow curvew    :n 0,208
 w   
A A A
(extrapolate from stress-strain 0test)
l  l0
%  A  l logarithmic
V stress A 0  l0 
stress:  l    l 0  l0 Flow curve

  ln(  1) l0
 A   strain
engineer  A Atrue
0 strain:
  w      1
Forming limit
curve
 The Forming Limit Curve is determined
by valid test procedures (e.g. Nakajima
test)
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 Material characteristics
Material data / R-values (Anisotropy)

 The R-value gives information about the flow directions in the material.
High R-value indicates good deep-drawing abilities.

R-value > 1  flow from width

R-value < 1  flow from thickness

r0 r45 r90 rm r0 r45 r90 rm

Modell 1,18 1,04 2,22 1,17 Modell 1,18 1,04 2,22 1,17
Test tief 0,50 0,50 0,50 0,50 Test hoch 2,50 2,50 2,50 2,50

Thinning Thinning

FLD by rupture FLD by rupture

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It may not be copied, disclosed or used for any purpose without the prior written consent of Tenneco Inc..
 Material characteristics
Material data / Hardening coefficient

 Hardening is the increase of the mechanical firmness caused by plastic

deformation. Material hardening results mostly on handicap / blocking of
transfers by the crystal lattices and / or grain boundaries. A low hardening
coefficient mean also a reduced stretch-forming ability.
 Depend on material characteristic & thickness our most wanted ferrite high-
grade steels has round about n  0,2 the austenite's n  0,4 usually.

Thinning Thinning

Fließspannung
log(kf)

n = tan a
log()
1 Umformgrad

FLD by rupture a = Verformungswiderstand bei  = 1 FLD by rupture

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It may not be copied, disclosed or used for any purpose without the prior written consent of Tenneco Inc..
 Forming Limit diagram to predict feasibility

Failure zone
cracks
Forming Limit Curve
(location depends on material & thickness)
easteregg

Safety zone

1 = major deformation
feasible feasible

2 = minor deformation

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It may not be copied, disclosed or used for any purpose without the prior written consent of Tenneco Inc..
Grenzformänderung Diagramm
(Quelle: K.Lange)

Achse: Tiefziehen Achse: Streckziehen

(Material fließt ausschließlich aus der Breite) (Material fließt gleichermaßen aus der Breite und aus der Dicke)

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It may not be copied, disclosed or used for any purpose without the prior written consent of Tenneco Inc..
*Attachment Major Take Away
Scrap Issues
same process and different quality of material
Valid material specification tolerance
current mat. specifications are not sufficient for actual requirements

High Material Quality Low Material Quality

Special agreement Usually delivered

with supplier material

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Copyright © Tenneco Inc. This document and the information embodied herein is the property of Tenneco Inc. and is disclosed in confidence for informational purposes only.
It may not be copied, disclosed or used for any purpose without the prior written consent of Tenneco Inc..