Finite Element Predictions for a Cold Sheet Metal Forming Process Using Tetrahedral Mini-Elements

2011 ◽  
Author(s):  
Min-Cheol Lee ◽  
Sang-Hyun Sim ◽  
Jae-Gun Eom ◽  
Man-Soo Joun ◽  
Wan-Jin Chung
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Three Dimensional ◽  
Thickness Variation ◽  
Forming Process ◽  
Rigid Plastic ◽  
Element Mesh ◽  
Metal Forming Process

In this paper, finite element prediction of a cold sheet metal forming process is investigated using solid elements. A three-dimensional rigid-plastic finite element method with conventional linear tetrahedral MINI-elements [1, 2] is employed. This technique has traditionally been used for bulk metal forming simulations. Both single- and double-layer finite element mesh systems are studied, with particular attention to their effect on the deformed shape of the workpiece and thickness variation. The procedure is applied to the well-known problem of the NUMISHEET93 international benchmark. The resulting predictions are compared with experimental observations found in the literature, and good agreement is noted.

scholarly journals Experimental And Theoretical Determination Of Forming Limit Curve

2015 ◽  
Vol 60 (3) ◽  
pp. 1881-1886
Author(s):  
J. Adamus ◽  
K. Dyja ◽  
M. Motyka
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Fracture Initiation ◽  
Forming Limit ◽  
Forming Process ◽  
Element Analysis ◽  
Metal Forming Process

Abstract The paper presents a method for determining forming limit curves based on a combination of experiments with finite element analysis. In the experiment a set of 6 samples with different geometries underwent plastic deformation in stretch forming till the appearance of fracture. The heights of the stamped parts at fracture moment were measured. The sheet - metal forming process for each sample was numerically simulated using Finite Element Analysis (FEA). The values of the calculated plastic strains at the moment when the simulated cup reaches the height of the real cup at fracture initiation were marked on the FLC. FLCs for stainless steel sheets: ASM 5504, 5596 and 5599 have been determined. The resultant FLCs are then used in the numerical simulations of sheet - metal forming. A comparison between the strains in the numerically simulated drawn - parts and limit strains gives the information if the sheet - metal forming process was designed properly.

Finite Element Modelling in Ultrasonic Sheet Metal Forming

2012 ◽  
Vol 445 ◽  
pp. 3-8 ◽  
Author(s):  
Yusof Daud ◽  
Margaret Lucas ◽  
Khairur Rijal Jamaludin
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Ultrasonic Vibration ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Fe Model ◽  
Forming Process ◽  
Interface Friction ◽  
Metal Forming Process ◽  
Previous Experimental Study

Finite element (FE) model of die necking process of an aluminium hollow thin cylinder has been developed. The input parameters of material properties and coefficient of friction, µ for the model have been deducted from our previous experimental study. Later the models have been validated against experimental data as reported in the previous studies. For the die necking process, the FE model has successfully to predict how much the original diameter of the aluminium hollow cylinder can be maximised necked with and without applying ultrasonic vibration. FE models showed that the application of ultrasonic vibration during the necking process has reduced buckling of the cylinder body if compared to the necking process without ultrasonic. The benefit of applying ultrasonic vibration in sheet metal forming process has been related to the reduction of interface friction between die and specimen.

Comparisons of Explicit and Implicit Finite Element Methods for Sheet Metal Forming

2014 ◽  
Vol 936 ◽  
pp. 1836-1839 ◽  
Author(s):  
Lei Chen
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Explicit Method ◽  
Forming Process ◽  
The Past ◽  
Simulation Speed ◽  
Metal Forming Process ◽  
Complex Parts

Sheet metal forming is one of the most commonly practiced fabrication processes in industry. Numerical simulations of the complex parts are possible by finite element method in the past thirty years. The most important problem of the simulation is the reliability of the model. Static implicit method (SI) and dynamic explicit method (DE) were used to simulation sheet metal forming process. It was found that simulation speed in dynamic explicit software has large effect on the simulation results. The best simulation speed is 5~10 m/s. Compared with the simulation and experimental results of thickness, draw-in and CPU time, the DE method is preferred.

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