Sheet Metal Stamping Simulation

ANSYS Case Study

• Load Deformation
• Load Setup
• Load Stress
• Simulation Videos

Case Study Overview

ANSYS structural simulations provide fast, accurate FEA analysis of any type of mechanical loading to any structure of any material type.

This case study shows how Premier Tool Design (www.premiertooldesign.com) was able to correctly determine the amount of deflection expected at the tip of an injection moulding unit, due to its self mass. The main mass of the unit slides on two linear rails and overhangs the main structure, thereby raising a concern of too much deflection at the injection point, which may make the unit unusable.

By using StampingSimulation.com’s ANSYS simulation services, the client was able to assess the deflection magnitude and add stiffness to the structure to keep the deflection to within acceptable operational limits. Different scenarios, such as extra linear rails, could be quickly and easily assessed to determine the best configuration to keep the deflection low.

In addition, the induced stresses in the structure can be analysed, to determine if the structure will deform permanently or simply flex elastically under the given load. If the stress exceeds the material’s yield strength, it’s clear the material will suffer permanent deformation and may be unsafe. Using ANSYS simulation, it’s possible to determine the “safety factor” of any structure. In the case of this example, the stresses are well within the material limits and the result is “safe” for the given load. No permanent deformation is expected.

The cost of simulating in the design phase and correctly specifying the structure stiffness, far outweighs the cost of an unusable result on the shop floor. Without simulation, designers are forced to calculate by hand or guess how to achieve an acceptable result. Hand calculations often rely on simplifications, due to complex 3D geometry, and are not always straight forward. Using 3D solid data, ANSYS can analyse even the most complex assemblies, without compromising assumptions that are sometimes used in hand calculations. 
StampingSimulation.com offers ANSYS services on a job by job basis, to analyse any product, assembly, or structure with loads of any type. Advanced analysis options include determining natural frequency response, non-linear analysis, fatigue and cyclic loading analysis.

Premier Tool Design, LLC  (www.premiertooldesign.com) is a tool and die design firm that specializes in 3D solid designs for the sheet metal stamping industry.  They specialize in progressive die tooling but also excel in transfer and line dies as well.

• 

  Back to Top Load Deformation

  The color map shows the calculated deformation, due to the applied load, highlighting the maximum point.

• 

  Back to Top Load Setup

  The constraints setup determine where the object is supported and where the load is applied, including magnitude, type and direction of the load.

• 

  Back to Top Load Stress

• Back to Top Simulation Videos