Modelling and Simulation of Sheet Metal Forming Processes

Modelling and Simulation of Sheet Metal Forming Processes

Author: Marta C. Oliveira

Publisher: MDPI

Published: 2020-04-22

Total Pages: 254

ISBN-13: 3039285564

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The numerical simulation of sheet metal forming processes has become an indispensable tool for the design of components and their forming processes. This role was attained due to the huge impact in reducing time to market and the cost of developing new components in industries ranging from automotive to packing, as well as enabling an improved understanding of the deformation mechanisms and their interaction with process parameters. Despite being a consolidated tool, its potential for application continues to be discovered with the continuous need to simulate more complex processes, including the integration of the various processes involved in the production of a sheet metal component and the analysis of in-service behavior. The quest for more robust and sustainable processes has also changed its deterministic character into stochastic to be able to consider the scatter in mechanical properties induced by previous manufacturing processes. Faced with these challenges, this Special Issue presents scientific advances in the development of numerical tools that improve the prediction results for conventional forming process, enable the development of new forming processes, or contribute to the integration of several manufacturing processes, highlighting the growing multidisciplinary characteristic of this field.


Ductile Fracture in Metal Forming

Ductile Fracture in Metal Forming

Author: Kazutake Komori

Publisher: Academic Press

Published: 2019-10-11

Total Pages: 294

ISBN-13: 0128147733

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Ductile Fracture in Metal Forming: Modeling and Simulation examines the current understanding of the mechanics and physics of ductile fracture in metal forming processes while also providing an approach to micromechanical ductile fracture prediction that can be applied to all metal forming processes. Starting with an overview of different ductile fracture scenarios, the book then goes on to explain modeling techniques that predict a range of mechanical phenomena that can lead to ductile fracture. The challenges in creating micromechanical models are addressed alongside methods of applying these models to several common metal forming processes. This book is suitable for researchers working in mechanics of materials, metal forming, mechanical metallurgy, and plasticity. Engineers in R&D industries involved in metal forming such as manufacturing, aerospace, and automation will also find the book very useful. Explains innovative micromechanical modeling techniques for a variety of material behaviors Examines how these models can be applied to metal forming processes in practice, including blanking, arrowed cracks in drawing, and surface cracks in upset forging Provides a thorough examination of both macroscopic and microscopic ductile fracture theory


Ductile Damage Prediction in Sheet Metal Forming Processes

Ductile Damage Prediction in Sheet Metal Forming Processes

Author: Zhenming Yue

Publisher:

Published: 2014

Total Pages: 0

ISBN-13:

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The objective of this work is to propose a “highly” predictive material model for sheet metal forming simulation which can well represent the sheet material behavior under complex loading paths and large plastic strains. Based on the thermodynamics of irreversible processes framework, the advanced fully coupled constitutive equations are proposed taking into account the initial and induced anisotropies, isotropic and kinematic hardening as well as the isotropic ductile damage. The microcracks closure, the stress triaxiality and the Lode angle effects are introduced to influence the damage rate under a wide range of triaxiality ratios. The distortion of the yield surface is described by replacing the usual stress deviator tensor by a 'distorted stress' deviator tensor, which governs the distortion of the yield surfaces. For comparisons, the FLD and FLSD models based on M-K approach are developed.A series of experiments for three materials are conducted for the identification and validation of the proposed models. For the parameters identification of the fully coupled CDM model, an inverse methodology combining MATLAB-based minimization software with ABAQUS FE code through the Python script is used. After the implementation of the model in ABAQUS/Explicit and a systematic parametric study, various sheet metal forming processes have been numerically simulated. At last, through the comparisons between experimental and numerical results including the ductile damage initiation and propagation, the high capability of the fully coupled CDM model is proved.


Damage Mechanics in Metal Forming

Damage Mechanics in Metal Forming

Author: Khemais Saanouni

Publisher: John Wiley & Sons

Published: 2013-02-04

Total Pages: 397

ISBN-13: 1118600878

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The aim of this book is to summarize the current most effective methods for modeling, simulating, and optimizing metal forming processes, and to present the main features of new, innovative methods currently being developed which will no doubt be the industrial tools of tomorrow. It discusses damage (or defect) prediction in virtual metal forming, using advanced multiphysical and multiscale fully coupled constitutive equations. Theoretical formulation, numerical aspects as well as application to various sheet and bulk metal forming are presented in detail. Virtual metal forming is nowadays inescapable when looking to optimize numerically various metal forming processes in order to design advanced mechanical components. To do this, highly predictive constitutive equations accounting for the full coupling between various physical phenomena at various scales under large deformation including the ductile damage occurrence are required. In addition, fully 3D adaptive numerical methods related to time and space discretization are required in order to solve accurately the associated initial and boundary value problems. This book focuses on these two main and complementary aspects with application to a wide range of metal forming and machining processes. Contents 1. Elements of Continuum Mechanics and Thermodynamics. 2. Thermomechanically-Consistent Modeling of the Metals Behavior with Ductile Damage. 3. Numerical Methods for Solving Metal Forming Problems. 4. Application to Virtual Metal Forming.


Simulation of Continuous Damage and Fracture in Metal-forming Processes with 3D Mesh Adaptive Methodology

Simulation of Continuous Damage and Fracture in Metal-forming Processes with 3D Mesh Adaptive Methodology

Author: Fangtao Yang

Publisher:

Published: 2017

Total Pages: 0

ISBN-13:

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This work is part of the research carried out in the framework of a collaboration between the Roberval laboratory of the Compiègne University of Technology and the team within the framework of the project ANR-14-CE07-0035 LASMIS of the Charles Delaunay Institute of Technology University of Troyes. In this work, we present a three-dimensional adaptive Pi-methodology of finite elements to represent the initiation and propagation of cracks in ductile materials. An elastoplastic model coupled with the isotropic damage proposed by the LASMIS / UTT team is used. The targeted applications will mainly concern the metal forming. In this context, an updated Lagrangian formulation is used and frequent remeshing is essential in order to avoid the strong distortion of elements due to large plastic deformations and to follow the modifications of the topology resulting in the creation of cracks. The size of the new mesh must allow at a lower cost to accurately represent the evolution of the gradients of the physical quantities representative of the studied phenomena (plasticity, damage ...). We propose empirical indicators of size of elements based on the plastic deformation as well as on the damage. A piecewise defined curve represents the evolution of the element size according to the severity of the plasticity and, if appropriate, the damage. The cracks are represented by a method of destruction of elements which allows an easy description of the geometry and a simplified treatment of the cracking without any need for additional criteria. On the other hand, to allow a realistic description of the cracks, the latter must be represented by erosion smaller elements. An ABAQUS / Explicit@ solver is used with quadratic tetrahedral elements (C3DIOM), avoiding in particular the problems of numerical locking occurring during the analysis of structures in compressible or quasi-incompressible material. The control of the smaller mesh size is important in an explicit context. In addition, for softening phenomena, the solution depends on the mesh size considered as an intrinsic parameter. A study has shown that when the mesh is sufficiently refined, the effects of mesh dependence are reduced. In the literature, the costs of frequent meshing or remeshing are often considered prohibitive and many authors rely on this argument to introduce, with success, alternative methods that limit the cost of remeshing operations without eliminating them ( XFEM for example). Our work shows that the cost of local remeshing is negligible compared to the calculation. Given the complexity of the geometry and the need to refine the mesh, the only alternative to date is to use a mesh in tetrahedra. The strategy of local remeshing tetrahedron is based on a bisection method followed if necessary by a local optimization of the grid proposed by A. Rassineux in 2003. The remeshing, even local, must be accompanied by field transfer procedures on both nodal variables and integration points. Node variables are, as most authors do, transferred using finite element shape functions. The 3D field transfer at Gauss points and the many underlying problems have been relatively untouched in the literature. The main difficulties to be solved in order to ensure the "quality" of the transfer concern the limitation of numerical diffusion, the lack of information near borders, the respect of boundary conditions, the equilibrium, the calculation costs, the filtering of the information points, crucial problems in 3D where the number of Gauss points used is several hundred. We propose a so-called "hybrid" method which consists, initially, in extrapolating the data at the Gauss points, in the nodes by diffuse interpolation and then in using the finite element form functions to obtain the value at the point considered.


Multiscale Modelling in Sheet Metal Forming

Multiscale Modelling in Sheet Metal Forming

Author: Dorel Banabic

Publisher: Springer

Published: 2016-10-20

Total Pages: 416

ISBN-13: 3319440705

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This book gives a unified presentation of the research performed in the field of multiscale modelling in sheet metal forming over the course of more than thirty years by the members of six teams from internationally acclaimed universities. The first chapter is devoted to the presentation of some recent phenomenological yield criteria (BBC 2005 and BBC 2008) developed at the CERTETA center from the Technical University of Cluj-Napoca. An overview on the crystallographic texture and plastic anisotropy is presented in Chapter 2. Chapter 3 is dedicated to multiscale modelling of plastic anisotropy. The authors describe a new hierarchical multi-scale framework that allows taking into account the evolution of plastic anisotropy during sheet forming processes. Chapter 4 is focused on modelling the evolution of voids in porous metals with applications to forming limit curves and ductile fracture. The chapter details the steps needed for the development of dissipation functions and Gurson-type models for non-quadratic anisotropic plasticity criteria like BBC 2005 and those based on linear transformations. Chapter 5 describes advanced models for the prediction of forming limit curves developed by the authors. Chapter 6 is devoted to anisotropic damage in elasto-plastic materials with structural defects. Finally, Chapter 7 deals with modelling of the Portevin-Le Chatelier (PLC) effect. This volume contains contributions from leading researchers from the Technical University of Cluj-Napoca, Romania, the Catholic University of Leuven, Belgium, Clausthal University of Technology, Germany, Amirkabir University of Technology, Iran, the University of Bucharest, Romania, and the Institute of Mathematics of the Romanian Academy, Romania. It will prove useful to postgraduate students, researchers and engineers who are interested in the mechanical modeling and numerical simulation of sheet metal forming processes.