scholarly journals Development of a numerical compensation framework for geometrical deviations in bulk metal forming exploiting a surrogate model and computed compatible stresses

2021 ◽  
Author(s):  
Lorenzo Scandola ◽  
Christoph Büdenbender ◽  
Michael Till ◽  
Daniel Maier ◽  
Michael Ott ◽  
...  
Keyword(s):  
Finite Element ◽  
Surrogate Model ◽  
Metal Forming ◽  
Computer Aided Design ◽  
Transition Process ◽  
Reference Points ◽  
Compensation Method ◽  
Tool Geometry ◽  
Bulk Metal ◽  
Bulk Metal Forming

AbstractThe optimal design of the tools in bulk metal forming is a crucial task in the early design phase and greatly affects the final accuracy of the parts. The process of tool geometry assessment is resource- and time-consuming, as it consists of experience-based procedures. In this paper, a compensation method is developed with the aim to reduce geometrical deviations in hot forged parts. In order to simplify the transition process between the discrete finite-element (FE) mesh and the computer-aided-design (CAD) geometry, a strategy featuring an equivalent surrogate model is proposed. The deviations are evaluated on a reduced set of reference points on the nominal geometry and transferred to the FE nodes. The compensation approach represents a modification of the displacement-compatible spring-forward method (DC-SF), which consists of two elastic FE analyses. The compatible stress originating the deviations is estimated and subsequently applied to the original nominal geometry. After stress relaxation, an updated nominal geometry of the part is obtained, whose surfaces represent the compensated tools. The compensation method is verified by means of finite element simulations and the robustness of the algorithm is demonstrated with an additional test geometry. Finally, the compensation strategy is validated experimentally.

NUMERICAL SIMULATION OF BULK METAL FORMING BY MESHLESS METHOD

2009 ◽  
Vol 23 (06n07) ◽  
pp. 1615-1620 ◽  
Author(s):  
HONGSHENG LIU ◽  
ZHONGWEN XING
Keyword(s):  
Finite Element ◽  
Metal Forming ◽  
Meshless Method ◽  
Reproducing Kernel ◽  
Shape Function ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Structural Applications ◽  
Forming Analysis

Conventional finite element (FE) analysis of bulk metal forming processes often breaks down due to severe mesh distortion. In recent years, meshless methods have been considerably developed for structural applications. The main feature of these methods is that the problem domain is represented by a set of nodes, and a finite element mesh is unnecessary. This new generation of computational methods can avoid time-consuming meshing and remeshing. A meshless method based on reproducing kernel particle method (RKPM) is applied to bulk metal forming analysis. The displacement shape functions are developed from a reproducing kernel (RK) approximation that satisfies consistency conditions. The shape function is modified to impose essential boundary conditions accurately and expediently. A material kernel function that deforms with the material is introduced to assure the stability of the RKPM shape function during large deformations. A program based on RKPM is developed to simulate two examples of bulk metal forming process such as ring compression and cold upsetting, and numerical results demonstrate the performance of the meshless method in bulk metal forming analysis.

Forming Analysis of Housing with Small Fillets

2011 ◽  
Vol 80-81 ◽  
pp. 601-605
Author(s):  
Peng Yuan ◽  
Han Guan Xia ◽  
Xin Cun Zhuang ◽  
Hong Jun Zhao ◽  
Yi Dong ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Metal Forming ◽  
Dimensional Accuracy ◽  
Housing Production ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Process Sequence ◽  
Element Simulation ◽  
Forming Analysis

In order to ensure the dimensional accuracy of housing with small fillets, various forming factors have been analyzed in this paper based on finite element simulation. Through the analysis of the forming factors, the principle of die angle selection, the proper reverse drawing height in sizing process, sequence of sizing and applications of local sheet bulk metal forming in housing production were put forward, and some forming laws of housing with small fillets were concluded.

Advanced finite element analysis of die wear in sheet-bulk metal forming processes

2016 ◽  
Author(s):  
Bernd-Arno Behrens ◽  
Anas Bouguecha ◽  
Milan Vucetic ◽  
Alexander Chugreev ◽  
Daniel Rosenbusch
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Metal Forming ◽  
Element Analysis ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Die Wear

Experimental and Simulative Investigations of Tribology in Sheet-Bulk Metal Forming

2015 ◽  
Vol 639 ◽  
pp. 283-290 ◽  
Author(s):  
Florian Beyer ◽  
Heribert Blum ◽  
Dustin Kumor ◽  
Andreas Rademacher ◽  
Kai Willner ◽  
...  
Keyword(s):  
Finite Element ◽  
Half Space ◽  
Metal Forming ◽  
Rough Surfaces ◽  
Bulk Metal ◽  
Friction Law ◽  
Space Model ◽  
Bulk Metal Forming ◽  
Discretisation Error ◽  
The Law

Friction has a considerable influence in metal forming both in economic and technical terms. This is especially true for sheet-bulk metal forming (SBMF). The contact pressure that occurs here can be low making Coulomb’s friction law advisable, but also very high so that Tresca’s friction law is preferable. By means of an elasto-plastic half-space model rough surfaces have been investigated, which are deformed in such contact states. The elasto-plastic half-space model has been verified and calibrated experimentally. The result is the development of a constitutive friction law, which can reproduce the frictional interactions for both low and high contact pressures. In addition, the law gives conclusion regarding plastic smoothening of rough surfaces. The law is implemented in the framework of the Finite-Element-Method. However, compared to usual friction relations the tribological interplay presented here comes with the disadvantage of rising numerical effort. In order to minimise this drawback, a model adaptive finite-element-simulation is performed additionally. In this approach, contact regions are identified, where a conventional friction law is applicable, where the newly developed constitutive friction law should be used, or where frictional effects are negligible. The corresponding goal-oriented indicators are derived based on the “dual-weighted-residual” (DWR) method taking into account both the model and the discretisation error. This leads to an efficient simulation that applies the necessary friction law in dependence of contact complexity.

Metal Forming and the Finite-Element Method

1989 ◽  
Author(s):  
Shiro Kobayashi ◽  
Soo-Ik Oh ◽  
Taylan Altan
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Metal Forming ◽  
Computer Aided Design ◽  
The Finite Element Method ◽  
Forming Technology ◽  
Computer Aided ◽  
Deformation Mechanics ◽  
Aided Design ◽  
Element Method

The application of computer-aided design and manufacturing techniques is becoming essential in modern metal-forming technology. Thus process modeling for the determination of deformation mechanics has been a major concern in research . In light of these developments, the finite element method--a technique by which an object is decomposed into pieces and treated as isolated, interacting sections--has steadily assumed increased importance. This volume addresses advances in modern metal-forming technology, computer-aided design and engineering, and the finite element method.

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