Patent Application
20130325424
The present invention generally relates to creation of a computerized model for mechanical computer aided engineering (CAE) analysis, more particularly to systems and methods of creating a computerized model for a deep draw manufacturing simulation of a sheet metal part.
Sheet metal forming has been used in the industry for years for creating metal parts from a blank sheet metal, for example, automobile manufacturers and their suppliers produce many parts using sheet metal forming. One of the most used sheet metal forming processes is deep drawing, which involves a hydraulic or mechanical press pushing a specially-shaped punch into a matching die with a piece of blank sheet metal in between. Exemplary products made from this process include, but are not limited to, car hood, fender, door, automotive fuel tank, kitchen sink, aluminum can, etc. In some areas of the die, the depth of a part or product being made is generally more than half its diameter. As a result, the blank is stretched and therefore thinned in various locations due to the geometry of the part or product. The part or product is only good when there is no structural defect such as material failure (e.g., cracking, tearing, wrinkling, necking, etc.).
In order to successfully manufacture a sheet metal part, many of the today's manufactures uses computer or numerical simulations (e.g., Computer Aided Engineering Analysis (CAE)). One useful computer simulation is based on finite element analysis (FEA), which is a computerized method widely used in industry to model and solve engineering problems relating to complex systems. FEA derives its name from the manner in which the geometry of the object under consideration is specified. With the advent of the modern digital computer, FEA has been implemented as FEA software. FEA software can be classified into two general types, implicit FEA software and explicit FEA software. Implicit FEA software uses an implicit equation solver to solve a system of coupled linear equations. Such software is generally used to simulate static or quasi-static problems. Explicit FEA software does not solve coupled equations but explicitly solves for each unknown assuming them uncoupled. Explicit FEA software usually uses central difference time integration which requires very small solution cycles or time steps for the method to be stable and accurate. Explicit FEA software is generally used to simulate short duration events where dynamics are important such as impact type events.
In simulating of deep draw manufacturing of a sheet metal part, a number of FEA models must be defined and assigned in a computer system for an application module to perform the simulation. Prior art approaches have been generally depending upon knowledge of the user. It would therefore desirable to have improved systems and methods of creating computerized model for a deep draw manufacturing simulation of a sheet metal part.
This section is for the purpose of summarizing some aspects of the present invention and to briefly introduce some preferred embodiments. Simplifications or omissions may be made to avoid obscuring the purpose of the section. Such simplifications or omissions are not intended to limit the scope of the present invention.
Systems and methods of creating a computerized model for a deep draw manufacturing simulation of a sheet metal part are disclosed. According to one aspect of the invention, a series of computer generated visual diagrams are sequentially displayed upon receipt of a request from the user. The request is for creating a computerized model for a specific type of deep draw manufacturing simulation. The computerized model includes certain number of components for each particular type of simulations. The diagrams are configured for attracting the user's attention as to which component is being processed. Each diagram includes icons displayed in three different indicative schemes. The first indicative scheme shows components that have not been processed. The second indicative scheme shows a currently-processed component, while the third indicative scheme shows previously-processed components. The order of the series of diagrams is predetermined for each particular type of simulation hence minimizing human error in creation of the computerized model.
According to another aspect, the first indicative scheme is configured to show component in red color, the second in flashing yellow and the third in green.
Objects, features, and advantages of the present invention will become apparent upon examining the following detailed description of an embodiment thereof, taken in conjunction with the attached drawings.
These and other features, aspects, and advantages of the present invention will be better understood with regard to the following description, appended claims, and accompanying drawings as follows:
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will become obvious to those skilled in the art that the present invention may be practiced without these specific details. The descriptions and representations herein are the common means used by those experienced or skilled in the art to most effectively convey the substance of their work to others skilled in the art. In other instances, well-known methods, procedures, and components have not been described in detail to avoid unnecessarily obscuring aspects of the present invention.
Reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, the order of blocks in process flowcharts or diagrams representing one or more embodiments of the invention do not inherently indicate any particular order nor imply any limitations in the invention.
Embodiments of the present invention are discussed herein with reference to
Referring first to
Product surface contains the desired pattern/shape of a sheet metal part at the end of the forming process followed by a trimming operation. Binder section is configured for holding the blank during the forming process. Addendum section provides a buffer or transition zone between the product design surface section and the binder section. After the blank is shaped by the punch, the sheet metal part is cut out along the enclosed trim lines. A well or properly defined trim line allows the manufacturer to convert a blank into its final configuration either directly or faster hence significantly reducing the manufacturing costs of a sheet metal part.
For simulating a deep drawing manufacturing of a sheet metal part, a number of different types of simulation are performed.
Process 300 starts in an “IDLE” state until a request from a user is detected at test 302. The request indicates that the user is desirous of creating a computerized model for a specific type of deep draw manufacturing simulation. Exemplary types of simulations can be found in
Upon detection of the user request at step 304, process 300 displays a visual diagram on a computer monitor operatively adapted to a computer system (e.g., computer system 600 of
After the initial setup has been completed, process 300 starts processes the creation of the computerized model. In particular, components of a computerized model are processed (e.g., defined by the user) in a predetermined order (e.g., an order programmed in the computerized model creation application module). At step 306, upon a directive from the user, process 300 highlights the icon corresponding to a currently-processed component with a second indicative scheme. Process 300 also displays icons corresponding to previously processed components with a third indicative scheme. The second indicative scheme is configured to attract user the user's attention for the currently-processed component, while the third indicative scheme is for those components have been processed.
At step 308, process 300 prompts the user to associate a computerized mesh (e.g., a finite element analysis mesh) to the highlighted or currently-processed component. Next, at test 310, it is determined whether another component of the computerized model needs to be processed. If “yes”, process 300 moves back to repeat steps 306-308 until there is no more component to be processed. Then, process 300 moves back to the “IDLE” state waiting for another user request.
To demonstrate three different indicative schemes for displaying icons in a visual diagram, an exemplary series of a deep draw manufacturing simulation model creation is shown in
Next, when the first component, die, is being processed, the first icon 501 is highlighted with a second indicative scheme (dotted lines) in
According to one embodiment, first, second and third indicative schemes can be configured with three different colors on a color computer monitor. According to another embodiment, the second indicative scheme is configured with a flashing display to emphasize the currently-processed component. For those of ordinary skill in the art would appreciate many different well-known schemes to represent three indicative schemes.
According to one aspect, the present invention is directed towards one or more computer systems capable of carrying out the functionality described herein. An example of a computer system 600 is shown in
Computer system 600 also includes a main memory 608, preferably random access memory (RAM), and may also include a secondary memory 610. The secondary memory 610 may include, for example, one or more hard disk drives 612 and/or one or more removable storage drives 614, representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. The removable storage drive 614 reads from and/or writes to a removable storage unit 618 in a well-known manner. Removable storage unit 618, represents a floppy disk, magnetic tape, optical disk, etc. which is read by and written to by removable storage drive 614. As will be appreciated, the removable storage unit 618 includes a computer usable storage medium having stored therein computer software and/or data.
In alternative embodiments, secondary memory 610 may include other similar means for allowing computer programs or other instructions to be loaded into computer system 600. Such means may include, for example, a removable storage unit 622 and an interface 620. Examples of such may include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an Erasable Programmable Read-Only Memory (EPROM), Universal Serial Bus (USB) flash memory, or PROM) and associated socket, and other removable storage units 622 and interfaces 620 which allow software and data to be transferred from the removable storage unit 622 to computer system 600. In general, Computer system 600 is controlled and coordinated by operating system (OS) software, which performs tasks such as process scheduling, memory management, networking and I/O services.
There may also be a communications interface 624 connecting to the bus 602. Communications interface 624 allows software and data to be transferred between computer system 600 and external devices. Examples of communications interface 624 may include a modem, a network interface (such as an Ethernet card), a communications port, a Personal Computer Memory Card International Association (PCMCIA) slot and card, etc. Software and data transferred via communications interface 624 are in the form of signals 628 which may be electronic, electromagnetic, optical, or other signals capable of being received by communications interface 624. The computer 600 communicates with other computing devices over a data network based on a special set of rules (i.e., a protocol). One of the common protocols is TCP/IP (Transmission Control Protocol/Internet Protocol) commonly used in the Internet. In general, the communication interface 624 manages the assembling of a data file into smaller packets that are transmitted over the data network or reassembles received packets into the original data file. In addition, the communication interface 624 handles the address part of each packet so that it gets to the right destination or intercepts packets destined for the computer 600. In this document, the terms “computer program medium” and “computer usable medium” are used to generally refer to media such as removable storage drive 614, and/or a hard disk installed in hard disk drive 612. These computer program products are means for providing software to computer system 600. The invention is directed to such computer program products.
The computer system 600 may also include an input/output (I/O) interface 630, which provides the computer system 600 to access monitor, keyboard, mouse, printer, scanner, plotter, and alike.
Computer programs (also called computer control logic) are stored as application modules 606 in main memory 608 and/or secondary memory 610. Computer programs may also be received via communications interface 624. Such computer programs, when executed, enable the computer system 600 to perform the features of the present invention as discussed herein. In particular, the computer programs, when executed, enable the processor 604 to perform features of the present invention. Accordingly, such computer programs represent controllers of the computer system 600.
In an embodiment where the invention is implemented using software, the software may be stored in a computer program product and loaded into computer system 600 using removable storage drive 614, hard drive 612, or communications interface 624. The application module 606, when executed by the processor 604, causes the processor 604 to perform the functions of the invention as described herein.
The main memory 608 may be loaded with one or more application modules 606 that can be executed by one or more processors 604 with or without a user input through the I/O interface 630 to achieve desired tasks. In operation, when at least one processor 604 executes one of the application modules 606, the results are computed and stored in the secondary memory 610 (i.e., hard disk drive 612). The status of the computerized model creation is (e.g., finite element analysis model) is reported to the user via the I/O interface 630 either in a text or in a graphical representation.
Although the present invention has been described with reference to specific embodiments thereof, these embodiments are merely illustrative, and not restrictive of, the present invention. Various modifications or changes to the specifically disclosed exemplary embodiments will be suggested to persons skilled in the art. For example, whereas one particular type of deep draw manufacturing simulation (3-piece air draw) has been described and shown, other types may be used, for example, toggle draw, trimming, etc. In summary, the scope of the invention should not be restricted to the specific exemplary embodiments disclosed herein, and all modifications that are readily suggested to those of ordinary skill in the art should be included within the spirit and purview of this application and scope of the appended claims.
