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Simulation software for sheet forming operations.
Stampack® includes an easy-to-use interface allowing fast definition of problem data and visualisation of results. Stampack® is available on PC and Unix platforms with the capacity to distribute the computation load over a network of processors.

Usage of computer simulation of the sheet stamping process enables the prediction of the final component shape, effects of dies and tools, effects of drawbeads and guides and effects of sheet coatings, allowing the anticipation of problems such as sheet rupture, wrinkling and springback, even before designs are finalised, dies have been manufactured and the first trials have been stamped.

This enables companies such as component designers, die manufacturers and the ultimate sheet stamping manufacturers to produce quality products, reducing trial-and-error methodologies and eliminating risk for quotations and predictions of time-to-market.


Can decoration module
This software module allows any image to be applied to the fianl formed can so that Stampack® can compute the original image to be printed on the flat sheet in order that no distortions occur. This computation therefore takes into account the important straining of the material during the forming process.

Multi stamping
This facility allows successive or simultaneous operations to be defined (e.g. deep drawing, cutting, flanging, etc.). Furthermore it is possible to:
- define more than 1 punch within a stage
- move the punches in arbitrary directions
- define the stamping process stages in any order
- freely specifying the order of the drawing, cutting, flanging, springback, etc.

The cutting facility allows the following cutting operations to be defined:
- relief cuts defining a single cut for stress or strain relief in the sheet
- holes for cutting arbitrary shapes
- trimming in order to trim the sheet edges

Fast-Springback using an implicit solution algorithm can be utilised after any operation within the stamping process. The springback stage may be calculated after any drawing, cutting or flanging operation. The next stage in the stamping process will continue using the deformed shape of the sheet as given after the springback.

Material Database
Stampack® provides a small database for standard sheet materials (steel and aluminium) which includes the Forming Limit Curves (FLC). Users may enhance this by saving their own materials into the database that will then be available to them for future use.

Tailor and Patchwork blanks
The sheet to be formed may be made as a tailor blank (a sheet made up of two or more sheets of different thickness welded together) or a patchwork blank (a sheet with smaller sheets welded to its upper or lower surface). The definition of tailor and patchwork blanks is done within the sheet (or blank) definition stage and allows different parts of the sheet geometry to be defined with different material properties and thicknesses. Use of the real sheet thickness is advised when carrying out simulations of this type since greater accuracy of the contact between the tools and the sheet is obtained.

Hydroforming of tubes and sheets
A facility for simulating hydroforming processes can be included as an additional module. This allows internal fluid pressures to be defined for the forming of tubular parts (input via pressure-time or flow rate-time curves) acting in addition to the movement of pistons or punches moving in arbitrary directions. The tube therefore expands under the combined action of the pistons and pressure and fills the die cavity to obtain the final part.Forming or counter-die pressures may be specified for sheet hydroforming using a pressure-time curve. The sheet deforms either according to the punch movement (with the pressure as a counter-die) or by filling the die cavity due to the pressure on the sheet surface.

Tool wear
Stampack® automatically calculates tool wear and provides qualitative output for the user to evaluate. The range of tool wear is from 0 to 1 since quantitative measurement dependent on too many parameters making it difficult and very costly to obtain (this may be done in collaboration with users who have specific needs).

Blank marking and scratching
Qualitative visualization of the marking on the blank created by the press tools and drawbeads can be obtained (a fixed range between 0 and 1 is used).

Original sheet development
By defining a boundary line on the final deformed sheet Stampack® can determine the original sheet development that would correspond to this shape. This enables the user to obtain a new proposal for the initial blank shape in order to achieve savings in material. The original blank development line may be exported as a line in a suitable CAD format.

Formability contours
Formability of the sheet provides an indicator of the deformation of the sheet and thus displays forming zones such as tight sheet, plane strain, loose sheet and wrinkling tendency on the final formed blank. On the other hand the forming limit of the sheet provides an indicator of the occurance of possible defects and thus displays zones of safety, wrinkle tendency, marginal or rupture.

Binder (or blankholder) pressure
Contour plots of the binder pressure acting on the sheet may be obtained to determine the uniformity of the binder action.

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