Simulation of bulk metal forming processes using one-step finite element approach based on deformation theory of plasticity

2010 ◽  
Vol 20 (2) ◽  
pp. 276-282 ◽  
Author(s):  
Peng WANG ◽  
Xiang-huai DONG ◽  
Li-jun FU
Keyword(s):  
Finite Element ◽  
Metal Forming ◽  
Deformation Theory ◽  
Bulk Metal ◽  
Finite Element Approach ◽  
Bulk Metal Forming ◽  
Theory Of Plasticity ◽  
Element Approach ◽  
One Step

Finite Element Analysis of the Axisymmetric Upsetting Process Using the Deformation Theory of Plasticity

1993 ◽  
Vol 115 (4) ◽  
pp. 450-458 ◽  
Author(s):  
K. D. Vertin ◽  
S. A. Majlessi
Keyword(s):  
Finite Element ◽  
Metal Forming ◽  
Deformation Theory ◽  
Computation Time ◽  
Published Data ◽  
Element Formulation ◽  
Solid Cylinder ◽  
Element Analysis ◽  
Bulk Metal ◽  
Theory Of Plasticity

The deformation theory of plasticity is extended to the analysis of bulk metal forming problems. An elastic-plastic finite element formulation is developed and used to simulate solid cylinder and ring upsetting processes. The intent of this analysis is to demonstrate that the deformation theory yields solutions equivalent to the incremental theory, and requires less computation time. Predicted results are compared with published incremental finite element solutions and experimental measurements. Deformation theory results are in agreement with published data for many forming conditions. The performance of the formulation gradually degraded with increasing deformation and friction, and possible causes for this behavior are discussed.

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.

A General Finite Element Approach for Porous and Non-Porous Metal-Forming Processes

1994 ◽  
Author(s):  
B. Sudhakar ◽  
John E. Jackson ◽  
William K. Rule ◽  
Imtiaz Haque
Keyword(s):  
Finite Element ◽  
Porous Materials ◽  
Metal Forming ◽  
Porous Metal ◽  
Two Dimensional ◽  
Powder Metal ◽  
Finite Element Approach ◽  
Numerical Tests ◽  
Element Approach ◽  
Good Agreement

Abstract A rigid-viscoplastic finite element flow formulation based on the Doraivelu et al. constitutive equation for a porous material is presented. The plasticity equations developed were incorporated into a two-dimensional Eulerian-based finite element code, CFORM. The code predicts the principal variables involved in powder metal forging. Numerical tests performed with the simulation of porous and non-porous materials using this formulation showed good agreement with results from other researchers. Results of this study demonstrate the flexibility of this flow formulation approach in simulating forging for both porous and non-porous materials.

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