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Virtual Prototyping of Sheel Metal Processing Machine to Improve Capacity and Precision

ㆍProduct: Sheet Metal Processing Machine (Punching Machine)

ㆍAnalysis Goal: Accurately predict the behavior of the dynamic effects caused by the coupling of the inertial load with the structural flexibility under various operating conditions

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The design of the Sheet Metal Processing Machine (Punching Machine) must take into account the dynamic effects caused by the coupling of the inertial load with the structural flexibility. During acceleration and deceleration, the machine structure undergoes small deformations that can cause oscillations at the end of the movement, especially with higher payloads.

RecurDyn provides a robust tool for efficiently creating and analyzing virtual prototypes capable of reproducing the dynamic behavior of the sheet metal processing machine under different operating conditions.

Process of Sheet Metal Processing Machine Simulation

① Set up a Multi Flexible Body Dynamic model of the Sheet Metal Processing Machine

② Implement both linear guides and ball screws using the dedicated RecurDyn/MachineTool toolkit

③ Implement flexible bodies through the linear approach based on the modal condensation (Reduced Flexible body)

④ Create a sub-mechanism that reproduces the dynamic effects of the brushes table on to the moved metal sheet

⑤ Use the powerful RecurDyn expression editor to develop a custom non-linear analytical model that controls both normal and shear reaction forces

⑥ Simulate the dynamic behavior of the machine under different operating conditions

⑦ Post process outputs and identify the main goals

Sheet Metal Processing Machine Model and Simulation Results

Key Technologies for Analysis

ㆍ MFBD technology, which efficiently handles the flexibility of the system to evaluate the tool position with high accuracy.

ㆍ Robust solver that achieves the goals without needing powerful HPC and without exhibiting convergence problems

Toolkits for Efficient Sheet Metal Processing Machine Simulation

ㆍRecurDyn/Professional

ㆍRecurDyn/RFlex (Reduced Flex)

ㆍRecurDyn/MachineTool

Customer Challenges

• The market demands machines with increased payloads, shorter cycle times (capacity) and higher precision.

• Machines have to be designed and built in a shorter time, while keeping the development costs under control.

Solutions

• Introduce the dynamic simulation in the design chain to reduce the number of experimental tests / prototypes and to achieve a higher knowledge of the dynamic behavior of the machines.

Outcomes of Sheet Metal Processing Machine Simulation using RecurDyn

• The dynamic behavior of the punching machines is successfully and accurately reproduced

• The design of the machine control systems is improved which plays a crucial role in the final performance

• The number of design alternatives that will be tested on a physical prototype could be reduced

• RecurDyn can answer many design questions such as:

- Why is the system vibrating that way?

- Where is the stiffness more needed?

- Can we reduce the thickness of guides arms?

- Is the system damped enough?

- What is the optimal design of the sheet metal processing machine?

And more.

Other Applications Related to Sheet Metal Processing Machine Simulation

◀ LCD Transfer Robot simulation using RecurDyn (MFBD and Control)

ㆍComparison of different operating conditions (different LCD sizes)

ㆍSimulation of abnormal operations

ㆍSimulation including controller

◀ High Pressure Cleaning Robot simulation using RecurDyn (MFBD and CFD coupling)

ㆍSimulation including controller

ㆍEvaluation of optimal cleaning conditions using a coupling with CFD

ㆍStress assessment using MFBD