A New Mesh Variables Mapping Method for Vehicle Crash Simulation with Considering Sheet Forming Effects

2011 ◽  
Vol 338 ◽  
pp. 245-250 ◽  
Author(s):  
Zhou Li ◽  
Xu Jing Yang
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Simulation Analysis ◽  
Thickness Distribution ◽  
Mapping Method ◽  
Vehicle Body ◽  
Element Analysis ◽  
Crash Simulation ◽  
Vehicle Crash

In finite element analysis for vehicle body components, there are different meshes between sheet metal forming and crashworthiness analysis. In order to transfer mesh variables between different mesh models, a new mapping method for mesh variables is proposed in this study based on an inverse isoparametric mapping. In this method, the mesh variables, such as thickness distribution, stress and strain, are mapped by accurately positioning crash model’s nodes to transfer data from the sheet metal forming model to crash model. As an example, this approach was applied to the crash simulation analysis for a vehicle front bumper bar. The results showed that this method allows to precisely transfer mesh variables from sheet metal forming analysis to crash simulation analysis with considering the forming effects. The efficiency and accuracy are thus improved for vehicle crash simulation with this approach.

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.

scholarly journals Effect of Process Parameters and Preheating Temperature on Surface Roughness and Thickness Distribution in Hole Flanging using Incremental Sheet Metal Forming

2019 ◽  
Vol 8 (12S2) ◽  
pp. 84-87
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Thickness Distribution ◽  
Research Work ◽  
Preheating Temperature ◽  
Incremental Sheet Metal Forming ◽  
Best Parameter ◽  
Hole Flanging

Incremental Sheet metal forming is a die less method of forming which offers high formability. In this research work; effect of step depth, tool rotation speed and preheating temperature on surface roughness and thinning of flange wall is investigated in hole flanging using incremental forming. The parameter optimization is carried out by Taguchi method. Grey relational analysis is carried out to obtain best parameter combination.

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.

APPLICATION OF FORMING LIMIT CRITERIA BASED ON PLASTIC INSTABILITY CONDITION TO METAL FORMING PROCESS

2008 ◽  
Vol 22 (31n32) ◽  
pp. 5680-5685
Author(s):  
SEONG-CHAN HEO ◽  
TAE-WAN KU ◽  
JEONG KIM ◽  
BEOM-SOO KANG ◽  
WOO-JIN SONG
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Thin Sheet ◽  
Plastic Instability ◽  
Theoretical Background ◽  
Forming Limit ◽  
Preliminary Evaluation ◽  
Forming Process ◽  
Element Analysis

Metal forming processes such as hydroforming and sheet metal forming using tubular material and thin sheet metal have been widely used in lots of industrial fields for manufacturing of various parts that could be equipped with mechanical products. However, it is not easy to design sequential processes properly because there are various design variables that affect formability of the parts. Therefore preliminary evaluation of formability for the given process should be carried out to minimize time consumption and development cost. With the advances in finite element analysis technique over the decades, the formability evaluation using numerical simulation has been conducted in view of strain distribution and final shape. In this paper, the application of forming limit criteria is carried out for the tube hydroforming and sheet metal forming processes using theoretical background based on plastic instability conditions. Consequently, it is confirmed that the local necking and diffuse necking criteria of sheet are suitable for formability evaluation of both hydroforming and sheet metal forming processes.

Experimental Study on Residual Formability of Single Point Incrementally Formed Part

2019 ◽  
Author(s):  
Chetan P. Nikhare
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Forming Limit ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Conventional Process

Abstract A substantial increase in demand on the sheet metal part usage in aerospace and automotive industries is due to the increase in the sale of these products to ease the transportation. However, due to the increase in fuel prices and further environmental regulation had left no choice but to manufacture more fuel efficient and inexpensive vehicles. These heavy demands force researchers to think outside the box. Many innovative research projects came to replace the conventional sheet metal forming of which single point incremental forming is one of them. SPIF is the emerging die-less sheet metal forming process in which the single point tool incrementally forces any single point of sheet metal at any processing time to undergo plastic deformation. It has several advantages over the conventional process like high process flexibility, elimination of die, complex shape and better formability. Previous literature provides enormous research on formability of metal during this process, process with various metals and hybrid metals, the influence of various process parameter, but residual formability after this process is untouched. Thus, the aim of this paper is to investigate the residual formability of the formed parts using single point incremental forming and then restrike with a conventional tool. The common process parameters of single point incremental forming were varied, and residual formability was studied through the conventional process. The strain and thickness distribution were measured and analyzed. In addition, the forming limit of the part was plotted and compared.

Study on Loading Path Influences on the Thickness Distribution of TRIP Steels During Sheet Metal Forming

2009 ◽  
Author(s):  
W. J. Dan ◽  
W. G. Zhang ◽  
S. H. Li
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Martensite Transformation ◽  
Strain State ◽  
Thickness Distribution ◽  
Loading Path ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Forming Temperature

Loading path is one of key factors that influence the formability of sheet metal forming processes. In this study, the effect of several kinds of loading paths on the thickness distribution of TRIP steel is investigated in a deep drawing process based on a constitutive model accompanying the strain-induced martensite transformation. A kinetic model of transformation, that describes the relationship between the thickness distribution of a deep drawing process and the martensite transformation, is used to calculate the martensite volume fraction. The influences of loading path on the martensite transformation are also evaluated through the change in the stress-strain state, the forming temperature, the transformation driving force, the nucleation site probability and the shear-band intersection controlled by the stress-strain state and forming temperature at the minimum thickness location in the formed part.

Incremental sheet metal forming of Ti–6Al–4V alloy for aerospace application

2020 ◽  
Vol 44 (1) ◽  
pp. 56-64 ◽  
Author(s):  
R. Mohanraj ◽  
S. Elangovan
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Sheet Metal ◽  
Process Parameters ◽  
Experimental Work ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Geometric Accuracy ◽  
Element Analysis ◽  
Incremental Sheet Metal Forming

Driven by an increasing demand from the aerospace industry, thin sheet forming of titanium and its alloys is gaining prominence in scientific research. The design and manufacture of aerospace components requires the utmost precision and accuracy. It is essential to have good control over the process parameters of the forming process. Processes such as incremental sheet metal forming (ISMF) are highly controlled in the current manufacturing environment, but improvements in geometric accuracy and thinning are still needed. Although ISMF has greater process competence for manufacturing airframe structures with minimal costs, the process has its own negative effect on geometric accuracy due to elastic springback and sheet thinning. In this study, finite element analysis and experimental work are performed, considering process parameters such as spindle speed, feed rate, step depth, and tool diameter, to study the geometric accuracy and thinning of Ti–6Al–4V alloy sheet, while incrementally forming an aerospace component with asymmetrical geometry. The results are useful for understanding the geometric accuracy and thinning effects on parts manufactured by single point incremental forming (SPIF). Results from finite element analysis and experimental work are compared and found to be in good agreement.

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