Simulation of Deep Drawing process for sheet metal

In one of the class at TU Graz, I learned using a Swizz software called Autoform. The software is expensive but very useful tool. You define your Die, Punch, and Blank by loading your CAD software files, and then define certain properties regarding them in various options in software. The software is easy to use. After pre processing process, the solver makes the calculations for about 5 minutes to reach post processing, and you can then get required simulation of entire deep drawing process. The meshing is automatically generated, and is not very precise as forming processes simulation does not require very fine meshing. You can see the video above, of Simulation I did in Autoform and the important pictures from the simulation process that you can understand just by watching the pictures.

Machining Spur teeth gear on VMC

Here, I received an another machining challenge. The above gears has there centre offset, that means there bores are not in the center of circle, which further means, they can not be machined by hobbing machine, as it requires fixed center of work piece, around which work piece rotate and teeth are cut. So, we decided to machine it on VMC machine, as the gears did not required much precision, or smooth meshing. To do so, we first designed the tooth profile for above gears, then using CAM, we programmed desired tool motion, and the gear teeth were machined. The fibre gears  have 39 teeths with 4 module. The end mill used on VMC to machine them was of 3mm diameter.