ESI Numisheet 2008 BM03

Hot Forming Simulation in PAM-STAMP
Numisheet Benchmark BM03
More information in https://myesi.esi-group.com/
Copyright © ESI Group, 2013. All rights reserved. 1

NOTE
This working document and related know-how herein

provided by ESI Group subject to contractual conditions are
to remain confidential. The client shall not disclose the
documentation and/or related know-how in whole or in part
to any third party without the prior written permission of ESI
Group.
Copyright © 2013, ESI Group. All rights reserved.
Copyright © ESI Group, 2013. All rights reserved.

Contents
Hot Forming
Review of Hot Forming Processes
Review of Hot Forming Simulation
Hot Forming Simulation Using PAM-STAMP
Data Preparation
Simulation Setup (forming, quenching, cooling on air)
Post Processing
Step by Step Simulation Set Up
3
Hot Forming
REVIEW OF HOT FORMING PROCESSES
4
Review of Hot Forming:
Process
Source: Virginia commonwealth University/CPF
Metal blanks are heated to high temperature to improve formability, reduce

forming force, and increase geometrical accuracy
5
Review of Hot Forming:
Process Chain
Indirect:
Hot
Preforming Heating Transport stamping Quenching
Hot
Direct: Heating Transport stamping Quenching
~ 300 sec ~ 5 sec < 1 sec 5 - 20 sec

> 910 oC 950-800 oC > Ms 800 - 20 oC
~ -20 oC/sec Crit. cooling rate
(th=1.5mm) ~ -25 oC/sec
(22MnB5)
6
Applications of Hot Formed
Automotive Components
A-pillar reinforcement
Bumper
Hood reinforcement
Door beams
B-pillar
reinforcement Side rail member
7
Hot Forming Advantages /
Challenges
Advantages
Very complex shapes can be achieved with one operation
otherwise impossible
Very little residual stresses – no springback
Superior mechanical properties (1500 N/mm2 tensile strength)
No typical forming and springback disadvantages of AHSS and
UHSS
Challenges
High investment
Additional heating and cooling equipment
Additional handling and environment issues
8
Hot Forming
REVIEW OF HOT FORMING SIMULATION
9
Challenges
Hot forming is a process involving complex physics and

technologies
Stamping / deformation mechanics, temperature, phase
transformations, fluid flow (cooling systems)
Prototype is very expensive because:

Material is expensive
Tools are more expensive than cold stamping
Blank is hot (900°C)
Equipment is expensive (production line is ~ 7 Million €)
High financial investment and risk

Simulation is important to assess feasibility (both technically and
financially) before investment
10
Three Types of Simulations
Feasibility
To check the feasibility of the hot forming process (wrinkles,
rupture, hardness) with minimum simulation time, using a
constant tool temperature
Formability
To check the formability of the hot forming process (wrinkles,
rupture, hardness) with highest precision, using a variable tool
temperature depending on process conditions
Design of the cooling system

To validate your design of cooling channels
11
Major Aspects
Thermo-mechanical material model / blank

Temperature dependent deformation behavior
Strain Rate dependent deformation behavior
Phase transformations
Heat transfer (conduction, convection and radiation)
Tooling/blank interaction
Temperature, pressure, gap dependent heat transfer between blank
and tooling
Heat transfer between tooling and coolant
Cooling channel design
Quenching
Pure thermal
Thermo-mechanical
12
Hot Forming
HOT FORMING SIMULATION USING PAM-

STAMP 2G
13
Capabilities
Dedicated GUI for hot forming

simulation
Material Model considering both
temperature and strain rate effect
Heat transfer within blank, between
blank and tool (pressure and gap
dependent), blank/environment
(convection, radiation), tool/coolant
(cooling channel)
Phase transformation in forming and
quenching
Blank expansion (dilatation)
14
Feasibility
Stamping simulation Blank with phase Constant tool

transformations temperature
Quenching simulation Heat transfer blank /

(heat transfer with constant tool
contact pressure from forming)
Stamping
G, exch, H, exch, S Quenching
700°C-
Tblank 900°C
TS final (1)
Easy Set-up
Fast CPU time
Feasibility & production cycle time

Ttools
t
15
Formability
Stamping simulation Blank with phase Tool modeled with a

transformations thermal shell
Quenching simulation Blank dilatation Heat transfer blank / tool

(heat transfer depends on
evolution of the contact pressure
during quenching)
Stamping
G, exch, H, exch, S Quenching
700°C-
Tblank 900°C
Easy Set-up TS final (1)
Enhancement of feasibility
CPU time managed with DMP
Formability & shrinking
Process definition Ttools

t
(Blank size, Guide, spacer, tailored …)
16
Cooling Channel Validation – Solid
Tool
Quenching (heat transfer as a Blank with phase Solid elements for tools
function of gap & contact transformations with cooling channels
pressure taken from the forming
simulation Blank results from forming Tools convection with air
simulation
(with temperature and gap & contact Heat transfer between tool
Automatic cycles simulation pressure = heat transfer)
and water modeled with
Thermal exchange by convection
contact Tool /blank
Stamping Quenching Transfer Quenching Transfer

Easy Set-up
of cyclic calculation
Blank results from stamping
Validate the cooling channel

design t
Cycle 1 New cycle
17
Hot Forming
DATA PREPARATION
18
Material Properties: General Tabs
Three tabs gathered in material dialog

Mechanics / Thermal / Metallurgy
Thermal and Metallurgy toggles are optional
(data are stored in database)
Missing points inside LUT

are well managed
19
Hardening
Notes on Look-up Table

Hardening curves (plastic stress/strain) are available
but if desired, the user can enter his/her own data
If you enter your own data, enter enough points to
avoid excessive interpolation

Thermal and Metallurgical Properties
Thermal page:
Dissipation factor
E(T), (T)
Blank expansion by “dilatation coefficient” or
“thermal strain”
If Metallurgy activated, 4 tabs for each phase

appear :
Rho(T), K(T) and Cp(T) or H(T)
21
Thermal and Metallurgical Properties
Metallurgy page:
Definition of phase changes
22
Martensite and Diffusion Based
Transformations
Four phases are treated in PAM-STAMP 2G

Austenite
Ferrite
Bainite P(t)
Martensite
Reactions:
reactions by JOHNSON-MEHL-AVRAMI model
(diffusion controlled reaction, time dep.)
time log
(also available K=Peq/t , K’=(1-Peq)/t )

P(T)
(multiplication factors F, F’ for cooling rates)
reaction austenite martensite (diffusionless,

temperature dependant) described by
KOISTINEN-MARBUGER model
temperature
CCT data translator (for fields)
23
Initial Conditions for Phase
Transformations
If thermal is activated:
Initial temperature needs to be
defined
If metallurgy is activated:
Initial phase status needs to be
defined (usually austenite)
24
Other Thermal Properties
Attribute per object tool in “All stages”

To be defined only for thermal tools shell
(Formability process)
Note: Mesh needs to be oriented!
Thermal thickness = 6mm by default

Initial temperature
Thermal density
Conductivity Kzz(T)
Kxx=Kyy=0.1*Kzz
Cp(T) or H(T)
Can be loaded from material database
25
Some Remarks about Unit Systems
Unit for major Variables
26
More Details – Unit Conversion
27
Hot Forming
SIMULATION SETUP
28
Definition of Integration Points Through
Thickness for Blank and Tools
Surface blank: usually 1 (default value)

is sufficient for accuracy since blank is
not too thick like tools => save CPU
time!
Surface tools: 5 (default value) =>

needed to simulate temperature variation
through thickness in case of thermal
thick shell tools
29
Thermal Mass Scaling
New frame in CPU control

Value can be entered manually or
through wizard
Automatic = wizard applied on selected
object
The input value is the minimum length for
thermal time step
Thermal mass scaling should impact only few
and very small elements of the tools => The
goal is to optimize the thermal time step
Wizard rule: 20% of smallest radius in the tool
but should not impact more than “maximal
surface ratio” user value (2% by default).
30
Thermal Behavior of the Blank & Tool
Attribute per object in each stage

Not available for gravity and springback
stages => isothermal!
Blank initial dilatation (disabled for

tools, those are “cold”) purely
geometrical
Convection with ambient temperature
or cooling system (tool)
Radiation
Imposed temperature for tools in case
of feasibility process
Heat exchange depending on gap &
contact pressure
31
Heat Transfer Depending on Gap
and Contact Pressure
Below usual contact properties are displayed

Accurate contact is used
Heat transfer can be dependant on gap and contact pressure
Conduction area
Ch
Gap Function
Contact pressure
function
d
Convection area
32
Cooling of the Tool - Convection
Blank : Convection with air in case no gap or contact

Tools :
In case of thick shell thermal tool => free convection with tool
volume on lower fiber Tool surface
Tool volume
Free convection
In case of volume thermal tool => free convection on cooling

channel surfaces
33
Quenching
New stage type : Quenching

Global object Can be thermo-mechanics (Validation)
->quenching parameters If contact heat transfer depends on
(recomputed) contact pressure
If expansion effect needs to be simulated
Tools can be fully locked or under a press
force and blank must be free
CPU more expensive, but can be reduced
with VLSCF and/or TMS
Or purely thermal (Feasibility)
Contact pressure is picked from previous
stage and kept constant
All mesh is locked (Tools & Blank)
Note: in case of volume tools, quenching can be only
purely thermal!
Attention: Simulation time is used here
34
Cyclic Quenching
Target is Tool
Goal: Simulate the temperature cycle of tools during
the hot stamping of the few first parts
During the hot stamping of these few first parts, the
tools temperature is not yet stabilized under the
action of cooling system load and contact heat
transfer with the hot blank
The user wants to get with this simulation an idea
about the temperature stabilization time on the
tools.
The drawing phase is not included in cyclic
cooling
Each *.res file corresponds to the end of a
cycle
Attention: Simulation time is used here

35
Cyclic Quenching
Blank picked from stamping
heat transfer contact
And pressure
dependant (Gap)
Convection with ambient temperature
Initial surface Temp of the tool
QUENCHING TRANSFER
Water temperature (surface of cooling channels)

Convection between channels & tool
36
Cyclic Quenching
Simulation of the cycles until steady state
Stamping Quenching Transfer Quenching Transfer
Tblank
Ttools
Cycle 1 New cycle t
37
cyclic period of blank Initial Temperature attribute Cyclic Quenching
Sensor logical function of thermal contact
1
0
initial blank T
T Blank transfer time blank Quenching time
End Stamp blank T
blank T
Tool T
1st Stamp time Stamp time neglected
Cyclic cooling simulation
Picking from stamp

(Temperature, contact pressure …)
38
38
Cyclic Quenching
39
39
Hot Forming
SPECIFIC NUMERICAL CAPABILITIES
40
Blank thickness after stamping
Using TTS Elements
Areas with thickening
 high contact pressures & cooling

rates expected
Normal stress becomes important !
Contact pressure:
Stop on PINCH Driven till end, standard shell Driven till end, TTS

Using TTS Elements
The TTS element improves prediction of contact pressure when ironing happens, which is
most of the case. This results in more accurate heat exchange estimation and improved
quenching results. However using of suitable heat exchange functions (non-increasing
with higher pressure) reduce inaccuracy from overestimation of contact pressures in
pinching, which makes using of CPU-expansive TTS elements groundless.
On the contrary active pinch test is suppressing contact pressures at all  cooling
significantly underestimated. Pinch test is not recommended in hot forming simulation.
Temperature after 1th cycle quenching:
Stop on PINCH Driven till end, standard shell Driven till end, TTS

Hot Forming
POST-PROCESSING
43
Post Processing
Nodal contours:
Upper/Lower contact pressure (scalar)
Upper/Lower/membrane temperature (scalar)
Shell contours:
Mean internal heat flux (vector = (Energy/surface)/time)
Mean enthalpy (scalar= Energy/Mass)
Phase proportions (membrane fiber value)
Martensite / Austenite / Ferrite / Bainite
History
Object resultant history curve on phase proportions
Existing real time history output is available for thermal
New stop criteria : cyclic cooling
Hardness, cooling rate contour: V2012 new function
44
44
Recommendations
Mesh
Make sure the normal vectors of the blank mesh are oriented
CPU Time optimization:

Standard mass scaling and speed up (start with V2012.1)
VLSCF (can be as small as 0.001)
Thermal mass scaling (depending on tool mesh size)
Pure thermal quenching (feasibility)
Cleaning the tool meshes saves CPU & errors:

Possibility to use Thermal Mass Scaling
45
45
Engineering / Not Needed /
Limitations
Engineering
Martensite transformation depends only on temperature – can be modelled
in all cases as one material with one dilatation curve
Bainite transformation in soft zones can be modelled as one material with
one dilatation curve because of narrow bandwidth of cooling rates
Strain hardening must not depend on strain rates when phase
transformations happen
The blank must be formed when phase transformations start
Not needed / not available
Volume tool for stamping – would be too costly in terms of simulation time
Limitations:
Volume blank cannot be used with thermal tool shell or define user contact
thickness via UDA (User Defined Attributes)
Fixed elements are excluded from contact and heat transfer in Quenching
Do not fix blank nodes during quenching!
Heat transfer from blank to tool is restricted, when nodes of blank are in
contact (exactly above) with nodes or edges of the tool (and not with the
faces)
46
46
Two Methods
HOT STAMPING STEP BY STEP SETUP
47
Two Methods of Process Setup
From CAD files From PAM-DIEMAKER export

Please see slide 48 to Please see slide 80 to
begin process setup begin the process setup
from the CAD files of from the PAM-
each object DIEMAKER export file
48
NUMISHEET 2008 BM3
HOT STAMPING STEP BY STEP SETUP
49
Available Data
Tooling geometry (to be imported into PAM-STAMP 2G):

Numisheet08-BM03-Blank.igs
Numisheet08-BM03-Blank-holder.igs
Numisheet08-BM03-Die.igs
Numisheet08-BM03-Punch.igs
Material data provided by Numisheet: *The material data provided by Numisheet is

ESI_Numisheet_2008_BM03_ not used for this tutorial. Rather, the hot
forming material from the ESI public database
Material.psm is used instead. Numisheet has provided this
Tool_Material_CP.psm information as a reference for the process
Tool_Material_CP2.psm description provided below
Tool_Material_CP4.psm
Numisheet08-BM03-Materials.xls
*The process description is provided by

Process description: Numisheet and details the specific process
Numisheet08-BM03-Definition that this tutorial simulates.

Create a New PAM-STAMP 2G
Project
1. Open PAM-STAMP 2G and create a new project,

saving it in your working directory with the name
“ESI_Numisheet_2008_BM03”.
 Process: Stamp hot forming
 Solver type: PAM-AutoStamp

Import Tool Geometry (1/2)
1. Select Import tools CAD

2. Browse to the Data folder and select the
following 4 files:
Numisheet08-BM03-Blank
2 Numisheet08-BM03-Blankholder
Numisheet08-BM03-Die
Numisheet08-BM03-Punch
3. Select the “HOT FORMING” strategy for
3 meshing of tools
4. Click Import &Transfer
This step may take 1-2 minutes, as the CAD models are being
automatically meshed
The Import & Transfer function automatically meshes a CAD model and
transfers the resulting mesh into PAM-STAMP 2G. The Import & Check
function, on the other hand, automatically meshes a CAD model but
gives the user some options to check and manipulate the mesh before
4 importing it into PAM-STAMP 2G

Import Tool Geometry (2/2)
5. For each Source object

(except the Blank) select
the appropriate Target
group (i.e. Punch for
Punch, Blank holder for
5 Blankholder, and Die for
Die).
6. Click Transfer
53
Positioning the Geometry
The original geometries of the Numisheet tools are designed

in the opened position. For efficient work within PS2G it is
helpful to adjust the tools to the closed position, using the
menu item Geometry>Transformations>Translation
To translate geometries, display only the object you wish to
translate and click the select all icon. Type in the direction of
the vector along the appropriate axis and enter the
magnitude. Finally, hit Translate and click the deselect all
icon. The window (below right) illustrates how the translation
of the Die should be setup for this step. Once all parts are
translated, click Close.
1. Die 329.8 mm / - Z axis
2. Blankholder 130.1 mm / - Z axis
3. Blank 20 mm / - X axis
*Please note that strokes, positions,

displacements, motions and forces of are
designed based on the assumption that all
tools are in home (closed) position. Manual
Select All Deselect All modifications are needed to accommodate
other configurations.

Orientation of Tool Meshes
The orientation of tool meshes only needs to be checked when the tools have been directly
imported from a CAD file. If the tools are built from a source (i.e. punch source and blankholder
source), the mesh orientation will be correctly designated by the Tool editor
1. Display only the blankholder.

2. Open the menu dialog:
Geometry>Check/Repair>Orient elements…
ensure that Show normals is checked, and
(wrong orientation
for Blank Holder)
examine the orientation of the normals (white
arrows). Now, click on an element in that
object (it becomes the reference element and
displays a large green arrow in the direction of
that element’s normal).
3. Now click the Select all icon to select the
entire geometry. If the green arrow is oriented
properly (Blankholder +Z direction, Die -Z
direction, and Punch +Z direction), click
Orient, to ensure that all element normals face
the correct direction, otherwise click Reverse
Even if all elements appear to be properly oriented, it may
still be necessary to follow these steps as some
and then Orient.
improperly oriented normals may have gone unnoticed. If 4. Deselect all elements, and display the next tool
the tools are built from “Source” objects (i.e. punch source
repeating steps 1-3. Do this for the
and blankholder source), using the Tool editor, these
steps do not need to be performed as the Tool editor does Blankholder, Die, and Punch.
so automatically
Create Blank Outline
A blank outline only needs to be created if the initial blank geometry is imported from a CAD file.
Even though the blank geometry has already been meshed, a better quality blank mesh is obtained
by creating it from the blank outline, as it offers more control. With PAM-DIEMAKER for CATIA V5, a
blank outline can be imported with the tool geometries, making this step unnecessary.
1. Show the Numisheet08-BM03-Blank object only

2. Navigate to menu option: Geometry>Edition>3D curves
3
3. Click Create from… and select From free edges and click Apply
to create the curve, then Close
4. Now select the blank curve (“Curve 1”), click Add to object and
type “Blankline” for the object name. Click Add, then click Close on
the 3D curves window
5. Delete the Numisheet-BM03_Blank object by right clicking on it in
the visibility menu, selecting it in the pop up window, and checking
the Delete entities also… option, before clicking OK
4 5

Blank Definition
3
1. Click on Blank under the Set-up tab
2. Click on the + icon in the Blank editor
3. Set Name as “Blank” and Type as
“Surface Blank”. Click OK

Blank Definition:
Mesh
1. Select “Outline” for

definition type
2 2. Use “blankline” as the outline
3. Under advanced parameters
3 define Refinement under
curve as Imposed level: Level
4 2
4. Turn off Automatic meshing
5 and set mesh size to 16
As you can see, the refinement under curve setting determines the mesh size
around the outline of the blank, based on the initial mesh size. This leads to a
higher quality mesh

Blank Definition:
Material
1. Click on the Load a material icon
2. Select the “22MnB5-MPa-Thermal-Metallurgy_2012.1”
(mm.t.s.C) material in the Public database under hotforming
and click Apply (ignore warning that units are different than
project
4
1 3. Enter 1.97 mm for the thickness (taking into account thermal
expansion from 1.95 mm) and 810oC for temperature (the
blank is assumed to be 100% austenite at this point)
4. Click Apply and the initial blank mesh with material definition
will be created *The temperature that is
chosen, is the temperature of
5.
3 the blank by the time it has
left the oven and been
transferred to the tools. This
temperature is given in the
process description provided
by Numisheet. The
adjustment in thickness
derives from the equation:
L = 1 + T * 1.3e-5
Where L is the % change in
length, and T is the
temperature of the blank in
Celsius
2
Blank Definition:
Mesh Scaling
As the Blank we have just created represents the

original blank size (before heating), it doesn't
incorporate the thermal expansion through 810oC,
when the simulation is starting. To improve this, the
blank mesh must be expanded with the following
4 equation (used earlier with thickness):
L = 1 + T *1.3e-5 (L = 1.0104), where this time L is
the Scale factor.
3
1. Display and select (select all icon) the Blank
object only
2. Navigate to the menu option:
GeometryTransformationsScaling
3. Define Direction as “Isotropic”
4. Define the scale factor as 1.0104
*Center is irrelevant with Isotropic scaling
5. Click Scale then Close

Tool Preparation:
Spacer
1. Activate the Blankholder object only

2. Select several elements in Blankholder (see box 2 for
general location and shape) using the element select
icon (shown above), specific location and shape is not
2 important
3. Open GeometryTransformationsOffset
4. Set Distance to 1.175 mm (half of spacer thickness,
which will be defined later)
The offset elements will serve as a reference upon which the spacer will be built.
4 The spacer thickness will be distributed evenly on both sides of this reference
6 5. Click on the selected elements to view offset direction

(arrow appears)
6. Offset should be in +Z direction. If arrow is in opposite
direction, reverse the offset direction using the button
highlighted in the box to the left labeled 6
7. Activate the Generate in: option. Type “Spacer”
7 8. Click Offset to perform the operation, then click Close
8 The Generate in: option allows the user to create new elements as an offset of the
old ones, without altering the original elements. These new elements are placed in
the object selected by the user (or a newly created object like the spacer above). If
this is not checked, the original elements will be offset from there positions
Tool Preparation:
Blank Holder Walls
1. Display and select the Blankholder object only
2. Navigate to the menu option:
GeometryTransformationsWalls creation …
3. Set Direction 0 0 -1 in the Global System
4. Leave default values for Height and N Layers (10 and
1 respectively)
3 5. In the field Generate in choose the Blankholder
6. Click Create then Close, and deselect all
*It is recommend to build walls on force controlled tools (typically blank

4 holders) in order to prevent contact issues with the blank:

Tool Preparation:
Stamping Frame
1. Click on the Tools icon

2. In OP parameters, click on the + icon
by the OP direction label to add a new 1
Process frame (coordinate system) 2
3. Enter the Name “Stamping frame”, the
other attributes are pre-defined
4. Click OK
5. Use Definition type "Origin and vector" 5
3
6. Set Origin (0,0,0) and Vector (0 0 -1)
7. Click OK
As all public macros define the stamping direction along the +Z
axis (whereas the stamping direction in reference to the global 4
coordinate system is often -Z), it is often necessary to define a 6
stamping frame (Process frame) where the +Z axis is defined in
the direction of the -Z axis of the global coordinate system and to
set the Process frame as this Stamping Frame. 7

Process Definition:
Process Macro
1. Click on Process and select the + icon

to load a new macro
2. Browse to
1 \Stamp\Hotforming\Validation\
and select
“HF_Validation_SingleAction_MPa.ksa”
3. Click Open

Process Definition:
Groups and Stages
1. In the pop up Customize dialog, activate the

Blank, Die, Punch, Blankholder, Spacer,
History_nodes and History_elements
2. Under Stages, activate Gravity, Holding,
Stamping, Quenching, and Cooling on Air
3. Click OK
1
*Guides and Locator pins can be included, but were not provided for this
Benchmark

Process Definition:
Defining Groups
1. In the Group Window, double click Spacer
2. In the select objects window, select “Spacer” and
Click OK
3. Double click on History_elements.
4. Click on the Select element icon in the Select
objects window, display the blank, and select several
1 elements around the blank. Type “history_elements”
into the Select an object box, click Add to, then
select this object and click OK, then deselect all
5. Repeat 3-4 for “History_nodes:” except use the
Select nodes icon, and name the object
Select nodes icon
“history_nodes”
Select elements icon
History elements and history nodes allow the user to

visualize certain parameters (e.g. contact forces, energy,
stress and strains) at specific points over time.

Process Definition:
Gravity and Holding Parameters
Set the parameters shown in the marked area

by double clicking on each parameter. The
following values can be used:
• Spacer Thickness = 2.35 mm
• Blankholder stroke = -80 mm
• Minimum tool radius = 6
• Reference_temperature_blank = 20
• Friction = 0.35
• Function_gap = H_gap_Mpa
• Function_pressure = H_press_Mpa
(These functions, defined by the macro, can
be replaced by functions from the
Numisheet Process definition)
• Reference temperature_tool = 20
• Imposed_Temperature_Guides-Spacer = 70

Process Definition:
Parameters for Stamping, Quenching and
Cooling on Air
Some of the parameters defined in previous
stages (e.g. heat exchange functions) will be
transferred for the other stages and thus do not
need to be defined again. Those that do are
shown below:
• Blankholder_force = 200000 N
• Quenching time = 0.02 s
• Speed up activation = not activated
For Quenching and Cooling, the time given in the process
parameters is the simulation time. This value can be calculated
from Real Process Time * Velocity Scale Factor(VSF). Default
values for velocity scale factor are the following:
Holding: 0.1
Stamping: 0.05
Quenching: 0.001
Cooling = 0.001
The velocity scale factor is the coefficient that is used to correct
the plastic strain velocity of the material in order to accurately
simulate its behavior.

Process Definition:
Material selection
The material for the Blank and tools must be
defined:
1. Deactivate toggle "Keep" (material setup
from previous definition)
32 2. For each of the tools, click the Load
material icon
2 11 3. Define the remaining parameters
Blank material = 22MnB5-Mpa-Thermal-Metallurgy_2012.1
Blank thickness = 1.97 mm
Blank Initial temperature = 810
Tool material: tool-material-Mpa (under hotforming)
4. Clicking Apply will copy the setup to the

Attribute tree, then the macro dialog
window must be closed separately.
5. Clicking OK copies the setup in the
Attribute tree and closes the macro dialog
window.
5 4
Solver
1. Click on Solver
1 2. Set the appropriate solver

settings, depending on
2 your available hardware
3. Click OK
4. Set number of processors

and click OK
5. Click OK on the next

4 screen and the simulation
will start
3
70
Results: Gravity
Gravity Stage: Beginning
Gravity Stage: End
71
Results: Stamping
Temperature
Blank Temperature Die Temperature
72
Results: Stamping
Thinning / Thickness
Crack predicted close to transition

to the roof – similar like in reality.
73
Results: Stamping
Phase Transformation
Austenite Phase Fraction Martensite Phase Fraction
At the end of stamping, 100% Austenite and no Martensite= OK. No problems with
tool wear/cracking
74
Results: Quenching
Temperature Over Time
0s 4s 8s 12 s 20 s
75
Results: Quenching
Phase Transformations
Austenite Phase Fraction Martensite Phase Fraction
76
Results: Quenching
Phase Transformations / Cooling rate diagram
Phase Fraction dep. on Temperature Cooling Rate dep. on Temperature
77
Results: Temperature
Quenching Cooling on Air
78
Results: Martensite
79
Results: Hardness
80

ESI Numisheet 2008 BM03

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ESI Numisheet 2008 BM03

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Hot Forming Simulation in PAM-STAMP

Numisheet Benchmark BM03

More information in https://myesi.esi-group.com/

Copyright © ESI Group, 2013. All rights reserved. 1

This working document and related know-how herein

Copyright © 2013, ESI Group. All rights reserved.

Copyright © ESI Group, 2013. All rights reserved.

Step by Step Simulation Set Up

REVIEW OF HOT FORMING PROCESSES

Source: Virginia commonwealth University/CPF

Metal blanks are heated to high temperature to improve formability, reduce

~ 300 sec ~ 5 sec < 1 sec 5 - 20 sec

REVIEW OF HOT FORMING SIMULATION

Hot forming is a process involving complex physics and

Prototype is very expensive because:

High financial investment and risk

Design of the cooling system

Thermo-mechanical material model / blank

HOT FORMING SIMULATION USING PAM-

Dedicated GUI for hot forming

Stamping simulation Blank with phase Constant tool

Quenching simulation Heat transfer blank /

Fast CPU time

Feasibility & production cycle time

Stamping simulation Blank with phase Tool modeled with a

Quenching simulation Blank dilatation Heat transfer blank / tool

CPU time managed with DMP

Formability & shrinking

Process definition Ttools

Stamping Quenching Transfer Quenching Transfer

Blank results from stamping

Validate the cooling channel

Three tabs gathered in material dialog

Missing points inside LUT

Notes on Look-up Table

Copyright © ESI Group, 2013. All rights reserved. 20

If Metallurgy activated, 4 tabs for each phase

Four phases are treated in PAM-STAMP 2G

(also available K=Peq/t , K’=(1-Peq)/t )

reaction austenite martensite (diffusionless,

Attribute per object tool in “All stages”

Thermal thickness = 6mm by default

Can be loaded from material database

Unit for major Variables

Surface blank: usually 1 (default value)

Surface tools: 5 (default value) =>

New frame in CPU control

Attribute per object in each stage

Blank initial dilatation (disabled for

Below usual contact properties are displayed

Blank : Convection with air in case no gap or contact

In case of volume thermal tool => free convection on cooling

New stage type : Quenching

Attention: Simulation time is used here

Initial surface Temp of the tool

Water temperature (surface of cooling channels)

Simulation of the cycles until steady state

Stamping Quenching Transfer Quenching Transfer

Cycle 1 New cycle t

End Stamp blank T

1st Stamp time Stamp time neglected

Cyclic cooling simulation

Picking from stamp

SPECIFIC NUMERICAL CAPABILITIES