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Visualization of Metal Forming Processes
Partners in this project
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Institute for Metal Forming (IBF), Aachen University
Prof. Reiner Kopp - Center for Computing and Communication (CCC), Aachen University, Virtual Reality group
Dr. Torsten Kuhlen
Duration
Finished in December 2002
Project description
Numerical simulation, especially the finite element method, plays an important role in metal forming technology. The permanently increasing computer performance allows to apply sophisticated mathematical models. The forming processes can be optimized with respect to the product quality, costs and production time. At the IBF a pre- and postprocessor PEP has been developed. Numerical simulation software like LASTRAN/SHAPE and LS-DYNA can be started from within PEP, and the resulting data can be imported, visualized and explored in ViSTA.
The Ring Rolling Mill
The ring rolling is a wide-spread technology in producing seamless rings. The goal of a project currently running at the IBF is about a simulation of the ring rolling process using the FEM method. The medium flow should be computed as exactly as possible, regard should be also taken to various process parameters as the real pre-form geometry, the radial and axial milling distances, thermal relations. Another approach is to simulate the growth of the ring by means of dynamic equations that can be calculated in real time, thus allowing to interact with the process from within a virtual environment for teaching and training purposes.
The Virtual Press
A model of a complete metal press aggregate based on a FEM simulation performed by LASTRAN/SHAPE has been created and imported into the virtual environment. The user can start an animation of the forming process or explore the particular steps. The most important properties, e.g., the deformation and tension, are color coded. The semitransparent material of the aggregate enables to demonstrate the functionality of its hidden parts to get a better insight into the technology.
Videos
- Interactive exploration of a metal forming process at the HoloBench (15 MB): Download (15 MB) or Streaming
- A simulation of a metal pressing process (2.6 MB): Download (2.6 MB) or Streaming
Gallery
Visualization of a metal forming process - temperature is colour coded
An interactive simulation of ring rolling mills.
A metal pressing process, visualization on an immersive display.