scholarly journals Concept development of a method for identifying friction coefficients for the numerical simulation of clinching processes

2021 ◽  
Author(s):  
Max Böhnke ◽  
Moritz Rossel ◽  
Christian R. Bielak ◽  
Mathias Bobbert ◽  
Gerson Meschut
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Test Method ◽  
Image Correlation ◽  
Pollutant Emissions ◽  
Friction Coefficients ◽  
Frictional Behavior ◽  
Metal Material ◽  
Metal Materials ◽  
Interface Pressures

AbstractIn order to reduce fuel consumption and thus pollutant emissions, the automotive industry is increasingly developing lightweight construction concepts that are accompanied by an increasing usage of aluminum materials. Due to poor weldability of aluminum in combination with other materials, mechanical joining methods such as clinching were developed and established in series production. In order to predict the relevant characteristics of clinched joints and to ensure the reliability of the process, it is simulated numerically during product development processes. In this regard, the predictive accuracy of the simulated process highly depends on the implemented friction model. In particular, the frictional behavior between the sheet metals as well as between the sheet metal and clinching tools has a significant impact on the geometrical formation of the clinched joint. No testing methods exist that can sufficiently investigate the frictional behavior in sheet materials, especially under high interface pressures, different relative velocities, and long friction paths, while allowing a decoupled consideration of the test parameters. This paper describes the development of further testing concepts based on a proven tribo-torsion test method for determining friction coefficients between sheet metal materials for the simulation of clinching processes. For this purpose, the correlation of interface pressure and the relative velocity between aluminum and steel sheet material in clinching processes is investigated using numerical simulation. Based on these findings, the developed concepts focus on determining friction coefficients at interface pressures of the above materials, yield stress, as well as the reproduction of the occurring friction conditions between sheet metal materials and tool surfaces in clinching processes using tool substitutes. Furthermore, wear investigations between sheet metal material and tool surface were carried out in the friction tests with subsequent EDX analyses of the frictioned tool surfaces. The developed method also allows an optical deformation measurement of the sheet metal material specimen by means of digital image correlation (DIC). Based on a methodological approach, the test setups and the test systems used are explained, and the functionality of the concepts is proven by experimental tests using different sheet metal materials.

Development of a Method for the Identification of Friction Coefficients in Sheet Metal Materials for the Numerical Simulation of Clinching Processes

2021 ◽  
Vol 883 ◽  
pp. 81-88
Author(s):  
Moritz Rossel ◽  
Max Böhnke ◽  
Christian Bielak ◽  
Mathias Bobbert ◽  
Gerson Meschut
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Predictive Accuracy ◽  
Experimental Tests ◽  
Friction Model ◽  
The Body ◽  
Testing Method ◽  
Aluminum Sheets ◽  
Metal Materials ◽  
Frictional Coefficients

In order to reduce the fuel consumption and consequently the greenhouse emissions, the automotive industry is implementing lightweight constructions in the body in white production. As a result, the use of aluminum alloys is continuously increasing. Due to poor weldability of aluminum in combination with other materials, mechanical joining technologies like clinching are increasingly used. In order to predict relevant characteristics of clinched joints and to ensure the reliability of the process, it is simulated numerically during product development processes. In this regard the predictive accuracy of the simulated process highly depends on the implemented friction model. In particular, the frictional behavior between the sheet metals affects the geometrical formation of the clinched joint significantly. This paper presents a testing method, which enables to determine the frictional coefficients between sheet metal materials for the simulation of clinching processes. For this purpose, the correlation of interface pressure and the relative velocity between aluminum sheets in clinching processes is investigated using numerical simulation. Furthermore, the developed testing method focuses on the specimen geometry as well as the reproduction of the occurring friction conditions between two sheet metal materials in clinching processes. Based on a methodical approach the test setup is explained and the functionality of the method is proven by experimental tests using sheet metal material EN AW6014.

scholarly journals Three-Dimensional Finite Element Numerical Simulation and Analysis of Solid-State Processing of Metal Material

Complexity ◽  
2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Guang Su ◽  
Aimin Zhang
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Solid State ◽  
Three Dimensional ◽  
Current Status ◽  
3D Finite Element ◽  
Metal Material ◽  
Finite Element Numerical Simulation ◽  
Metal Materials ◽  
State Processing

Solid-state processing of metal material is a very complex physical and chemical process, which is coupled by a series of variations including heat transfer, momentum transfer, mass transfer, and phase change. Applying three-dimensional (3D) finite element numerical method to the simulation of solid-state processing can perform analysis of metal material’s forging processes before production trial production, can obtain their relevant information such as material flow law, temperature field, and strain field under the minimum physical test conditions, thereby predicting metal material’s forming defects and improving their forging quality. On the basis of summarizing and analyzing previous research works, this paper expounded the current status and significance of solid-state processing of metal materials, elaborated the development background, current status, and future challenges of 3D finite element numerical simulation, introduced the discrimination method and free surface solution method of numerical simulation calculation, conducted finite element model’s geometric assumptions, material selection, element division, model establishment, parameter selection, and initial and boundary condition determination, and simulated and analyzed rheological casting, remelting heating, thixoforming, and rotary piercing processes of metal materials. The results show that the 3D finite element numerical method can not only simulate various processes of flow field, temperature field, stress field, and microstructure in solid-state processing but also can provide a reliable basis for effectively obtaining a reasonable description and finding a more optimized design plan for metal material processing in a short time, which plays an important role in understanding and analyzing solid metal forming process, controlling and optimizing process parameters, guiding and mastering rheological casting, and secondary heating and rotary piercing of metal materials.

Multi-Step Forward Finite Element Method for the Numerical Simulation of Sheet Metal Forming

2011 ◽  
Vol 474-476 ◽  
pp. 251-254
Author(s):  
Jian Jun Wu ◽  
Wei Liu ◽  
Yu Jing Zhao
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Mapping Method ◽  
Constitutive Relationship ◽  
Element Method

The multi-step forward finite element method is presented for the numerical simulation of multi-step sheet metal forming. The traditional constitutive relationship is modified according to the multi-step forming processes, and double spreading plane based mapping method is used to obtain the initial solutions of the intermediate configurations. To verify the multi-step forward FEM, the two-step simulation of a stepped box deep-drawing part is carried out as it is in the experiment. The comparison with the results of the incremental FEM and test shows that the multi-step forward FEM is efficient for the numerical simulation of multi-step sheet metal forming processes.

Numerical simulation of sheet metal drawing by Maslennikov's technique

2007 ◽  
Vol 187-188 ◽  
pp. 192-196 ◽  
Author(s):  
M. Yamashita ◽  
T. Hattori ◽  
N. Nishimura
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal

Comparison between an Advanced Numerical Simulation of Sheet Incremental Forming Using Adaptive Remeshing and Experimental Results

2013 ◽  
Vol 554-557 ◽  
pp. 1375-1381 ◽  
Author(s):  
Laurence Giraud-Moreau ◽  
Abel Cherouat ◽  
Jie Zhang ◽  
Houman Borouchaki
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Sheet Metal ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Computation Time ◽  
Experimental Results ◽  
Forming Process ◽  
Adaptive Remeshing

Recently, new sheet metal forming technique, incremental forming has been introduced. It is based on using a single spherical tool, which is moved along CNC controlled tool path. During the incremental forming process, the sheet blank is fixed in sheet holder. The tool follows a certain tool path and progressively deforms the sheet. Nowadays, numerical simulations of metal forming are widely used by industry to predict the geometry of the part, stresses and strain during the forming process. Because incremental forming is a dieless process, it is perfectly suited for prototyping and small volume production [1, 2]. On the other hand, this process is very slow and therefore it can only be used when a slow series production is required. As the sheet incremental forming process is an emerging process which has a high industrial interest, scientific efforts are required in order to optimize the process and to increase the knowledge of this process through experimental studies and the development of accurate simulation models. In this paper, a comparison between numerical simulation and experimental results is realized in order to assess the suitability of the numerical model. The experimental investigation is realized using a three-axis CNC milling machine. The forming tool consists in a cylindrical rotating punch with a hemispherical head. A subroutine has been developed to describe the tool path from CAM procedure. A numerical model has been developed to simulate the sheet incremental forming process. The finite element code Abaqus explicit has been used. The simulation of the incremental forming process stays a complex task and the computation time is often prohibitive for many reasons. During this simulation, the blank is deformed by a sequence of small increments that requires many numerical increments to be performed. Moreover, the size of the tool diameter is generally very small compared to the size of the metal sheet and thus the contact zone between the tool and the sheet is limited. As the tool deforms almost every part of the sheet, small elements are required everywhere in the sheet resulting in a very high computation time. In this paper, an adaptive remeshing method has been used to simulate the incremental forming process. This strategy, based on adaptive refinement and coarsening procedures avoids having an initially fine mesh, resulting in an enormous computing time. Experiments have been carried out using aluminum alloy sheets. The final geometrical shape and the thickness profile have been measured and compared with the numerical results. These measurements have allowed validating the proposed numerical model. References [1] M. Yamashita, M. Grotoh, S.-Y. Atsumi, Numerical simulation of incremental forming of sheet metal, J. Processing Technology, No. 199 (2008), p. 163 172. [2] C. Henrard, A.M. Hbraken, A. Szekeres, J.R. Duflou, S. He, P. Van Houtte, Comparison of FEM Simulations for the Incremental Forming Process, Advanced Materials Research, 6-8 (2005), p. 533-542.

Optimization for Stamping Process Parameters of Front Fender Based on Numerical Simulation Technology

2010 ◽  
Vol 102-104 ◽  
pp. 232-236 ◽  
Author(s):  
Zhi Feng Liu ◽  
Qi Zhang ◽  
Wen Tong Yang ◽  
Jian Hua Wang ◽  
Yong Sheng Zhao
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Process Parameters ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Simulation Analysis ◽  
Explicit Method ◽  
Simulation Technology ◽  
Stamping Process ◽  
Automotive Panel

According to the characteristic which is more and difficult to determine about the automotive panel forming factors, based on the dynamic explicit method, taking the typical automobile front fender for example, do the simulation analysis by using of DYNAFORM. On the premise of taking springback factors into account, analog the best stamping process parameters has been optimized from the analysis results after simulation such as sheet metal forming limited drawing(FLD)and sheet metal thinning drawing.

scholarly journals An Investigation of Dynamic Responses and Head Injuries of Standing Subway Passengers during Collisions

2018 ◽  
Vol 2018 ◽  
pp. 1-13 ◽  
Author(s):  
Yong Peng ◽  
Tuo Xu ◽  
Lin Hou ◽  
Chaojie Fan ◽  
Wei Zhou
Keyword(s):  
Numerical Simulation ◽  
Head Injury ◽  
Head Injuries ◽  
Dynamic Responses ◽  
Passive Safety ◽  
Friction Coefficients ◽  
Safety Design ◽  
Parametric Studies ◽  
Simulation Results ◽  
Set Up

With the development of the subway and the pressing demand of environmentally friendly transportation, more and more people travel by subway. In recent decades, the issues about passenger passive safety on the train have received extensive attention. In this research, the head injury of a standing passenger in the subway is investigated. Three MADYMO models of the different standing passenger postures, defined as baseline scenarios, are numerically set up. HIC15values of passengers with different postures are gained by systematic parametric studies. The injury numerical simulation results of various scenarios with different friction coefficients, collision acceleration, standing angle, horizontal handrail height, and ring handrail height are analyzed. Results show that the horizontal handrail provides better protection in the three different standing passenger postures. Different friction coefficients and the standing angle have great impact on the head injuries of passengers in three different scenarios. The handrail height also has some effects on head injury of passengers with different standing postures, so it is necessary to be considered when designing the interior layout of the subway. This study may provide guidance for the safety design of the subway and some advices for standing subway passengers.

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