3DEXPERIENCE CATIA Springback and Warp Compensation CAD Models

In manufacturing, it is rare for parts to turn out perfectly as designed. Engineers and technicians attempt to produce perfect products by designing manufacturing CAD models with compensation built in, controlling the manufacturing process, or fixing the product deformations on the shop floor. 3DEXPERIENCE CATIA allows product designers to create springback- and warp-compensated CAD modes directly from simulation data, scan data, and literal/empirical data. This article will walk you through the process of springback- and warp-compensated CAD model creation on the 3DEXPERIENCE platform.

Topics of Discussion:

• Industry Challenges
• Advantages of CAD Models with Springback and Warp Compensation
• Selecting Roles and Apps
• Applying Compensation from Simulation Data
• Applying Compensation from Scan Data
• Applying Compensation from Literal or Empirical Data

Industry Challenges

To manage springback and warp, many engineers and technicians attempt to:

• Fix product deformations directly on the shop floor
• Control the manufacturing process
• Design CAD models with built-in compensation based on predictions and past experiences.

These approaches are often time-consuming, costly, and prone to inaccuracy, with a significant negative impact when combined.

Imagine developing an accurate CAD model in advance to counteract springback and warp. This approach reduces or eliminates the time-consuming, costly trial processes at production sites.

Next, let's explore the key features of springback and warp compensation, and how it can benefit your product design work.

Advantages of CAD Models with Springback and Warp Compensation

Creating CAD models with springback and warp compensation often demands high CAD expertise, legacy knowledge, and heavy manual effort. With 3DEXPERIENCE CATIA, you can:

• Use dedicated apps and commands to create compensated models quickly, without extensive CAD skills.
• Work with existing CAD models and simulation/scan data in standard formats.
• Leverage literal or empirical data for specific part areas.

The 3DEXPERIENCE platform offers a comprehensive “all-in-one procedure” that integrates initial CAD design, simulation analysis, and the creation of springback- and warp-compensated CAD models. Unlike competitors’ “simulation-first” approaches, this unified workflow preserves parametric associativity between the original CAD model and the compensated CAD model, while eliminating issues related to file format conversion and data transfer.

In the following sections, we will walk through the process of creating compensated models using practical examples.

Selecting Roles and Apps

First, select or search for the Mechanical & Shape Engineer role on the 3DEXPERIENCE platform.

Launch the Virtual to Real Shape Morphing app.

Alternatively, search for the app by keyword.

Applying Compensation from Simulation Data

Morphing with Simulation Data

To create a morphed CAD model from simulation data, you can use the Morphing Wizard. This tool allows you to apply FEA results (more specifically, a displacement vector field) for morphing. If you wish, you can visualize the imported vector field’s displacement effects on the part.

So, where do these simulation data come from? In a conventional workflow, CAD modelers utilize simulation software to predict material flow and the forming tendencies of the shape they are designing. To do this, they export the geometry from their CAD environment, and it enters a separate CAE environment to produce displacement data in ODB, UNV, CSV, or another popular format, depending on the FEA solver used.

The more seamless process is to perform the simulation with the Abaqus-based 3DEXPERIENCE STRUCTURAL FEA tools. Everything is associative, and everything is stored in and is shareable from one data source, the 3DEXPERIENCE platform. No CAD or FEA data is exported, imported, or translated – everything is native, comes from a common database, and is subject to a common change and data management regime.

Designers who don’t have access to analysts or the appropriate simulation software can also hire FEA consultants to deliver the simulation results they need. GoEngineer offers such manufacturing process - FEA services.

Apply the morphing to complete the process. The image below shows a comparison between the original model and the compensated model.

Morphing CAD Model Using Manually Created Vector Field

If your design work involves greater complexity, such as morphing specific areas or manually creating a vector field using multiple mesh data files, you can use advanced features to gain more precise control. In this step, we will demonstrate the morphing process on a sheet metal part, where a vector field is created using multiple mesh data files.

The Shape Constraints command allows you to define surface areas or holes to preserve the original shapes.

The Vector Field command allows you to select mesh point files (nominal/deformation) to create a vector field. In areas lacking mesh data, the surface will follow the neighboring deformation.

Create a Vector Field Filter to (optionally) parametrize the control of potential distortions.

Apply the morphing to complete the process. The results can be solids, surfaces, wireframes, or meshes, so a single morphing definition can derive everything, from the die face to the trim lines.

Applying Compensation from Scan Data

You can also utilize scan data to generate a morphed CAD model. In this step, we will demonstrate the morphing process by creating a vector field based on a Deviation Analysis.

Open a scanned data and select the area to apply morphing. You can choose either the entire scan or, optionally, select a limited/filtered area to remove ‘noise’ and control how the entire part will morph. In the following example, the entire part is morphed based on only the large rectangular area of the scan.

Create Deviation Analysis for the vector field.

Apply the morphing using the vector field.

Observe the comparison between the original model, scan data, and compensated model.

Applying Compensation from Literal or Empirical Data

If you don’t have simulation or scan data but you still need to create a morphed surface, you can use various commands to utilize literal and/or empirical data. In this step, we will demonstrate the morphing process using construction geometry as reference elements.

Use reference elements such as surfaces or curves to guide morphing.

Apply the Shape Morphing command to select the reference and target elements.

Apply the morphing. Observe the comparison between the original model and the morphed surface.

Discover More

To learn more about the 3DEXPERIENCE springback and warp compensation method, please contact us.

GoEngineer offers end-to-end solutions on the 3DEXPERIENCE platform, including CAD modeling and FEA of manufacturing processes.

Learn more by visiting our 3DEXPERIENCE page or scheduling time with our Simulation Services team.

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