Experimental and finite element simulation methods for rate-dependent metal forming processes

An experimental procedure and a finite element simulation method for rate-dependent metal forming processes are developed. The development includes the formulation of a tangential stiffness matrix for an axisymmetric solid finite element with four node, eight degree of freedom, quadrilateral cross-section. The formulation includes the effects of elasticity, viscoplasticity, temperature, strain rate and large strains. The solution procedure is based on a Newton-Raphson incremental-iterative method which solves the non-linear equilibrium equations and gives temperatures and incremental stresses and strains. Three examples are studied. In example 1, finite element simulation for the upsetting of a cylindrical workpiece between two perfectly rough dies is performed and the results are compared with alternative finite element solutions. In examples 2 and 3, both experimental and finite element studies are performed for the upsetting of a cylindrical billet and the forging of a ball, respectively. Annealed aluminium 1100 workpieces are used in both examples. For the finite element analysis, uniaxial compression tests are first performed to provide the material properties. The tests generate elastic moduli and two sets of stress-strain curves (quasi-static and constant strain rate), which are used to establish a rate-dependent material model for input. For both examples 2 and 3, comparisons between the experimental and finite element simulation results for the forming force vs. die displacement relations and also for the deformed configurations show good agreement. The versatility of finite element methods allows for displaying detailed knowledge of the metal forming process, such as the distributions of temperature rise, yield stress, effective stress, plastic strain, plastic strain rate, forming forces and deformed configurations, etc. at any instance during the forming process.     

Automatic adaptive remeshing for finite element simulation of forming processes

An automatic remeshing scheme has been developed to enable finite element simulation of even complicated forming processes. It has been demonstrated that for many practical applications the incorporation of this technique in the existing computer codes is indispensable not only for more accurate solutions but sometimes just for striving to obtain solutions. In order to avoid the tedious procedures of, e.g. interrupting the analysis, performing rediscretization, mapping of current state variables and preparing the new set of boundary conditions, methods for automating the remeshing procedures and the related accuracy problems have been presented. Several examples, such as a heading process, an extrusion process through a square die, and a one-blow impression-die forging process with flash have been successfully tested out with this automatic remeshing scheme.     

A mesh re-zoning technique for finite element simulations of metal forming processes

Based on some fundamental properties of finite element approximations, a mesh re-zoning scheme is proposed for finite element simulations of metal forming problems. It is demonstrated that this technique is indispensable in analysing many difficult forming processes, especially when there exist corners or very irregular shapes on the boundaries. The algorithm is tested by a backward extrusion process and direct extrusion through a square die.     

Adaptive generation of hexahedral element meshes for finite element analysis of metal plastic forming process

A method for the adaptive generation of hexahedral element mesh based on the geometric features of solid model is proposed. The first step is to construct the refinement information fields of source points and the corresponding ones of elements according to the surface curvature of the analyzed solid model. A thickness refinement criterion is then used to construct the thickness-based refinement information field of elements from digital topology. The second step is to generate a core mesh through removing all the undesired elements using even and odd parity rules. Then the core mesh is magnified in an inside–out manner method through a surface node projection process using the closest position approach. Finally, in order to match the mesh to the characteristic boundary of the solid model, a threading method is proposed and applied. The present method was applied in the mesh construction of different engineering problems. The resulting meshes are well-shaped and capture all the geometric features of the original solid models.     

Plane strain finite element simulation of shear band formation during metal forming

A plane strain finite element formulation and solution procedure for shear band failure during the plane strain metal forming process are developed and presented. The large strain elastic-plastic formulation includes a 5-node 10-degree-of-freedom (d.o.f.) ‘crossed-triangle’ element, a 4-node 8-d.o.f. element with selective reduced integration, an 8-node 16-d.o.f. element and a 4-node 8-d.o.f. element with an embedded shear band. The formulation includes an elastic-plastic material model with a modified Gurson yield function and combined isotropic-kinematic hardening. The solution procedure is based on a Newton–Raphson incremental-iterative method with an orthogonal projection of zero or negative eigen-modes when required. Two different examples of plane strain tension test are studied with results compared with available numerical solutions to evaluate the present formulation and solution procedure of the four different elements. The results demonstrate that both types of the 4-node quadrilaterals are comparable to the 5-node crossed-triangle element as well as the 8-jiode element. To further validate and to demonstrate the predictive capability and practical applicability of the present development, two plane strain metal forming examples are investigated. The first application is a numerical simulation of a sheet-stretching test with results compared with experimental data for a commercially pure aluminium–magnesium 5182-O sheet. The load vs. extension history and the through-thickness strain are compared. The good agreement suggests that it is possible to numerically determine the parameters needed for the modified Gurson yield function. The second application is a numerical simulation of the formation of dead metal zones in the extrusion process. A plane strain extrusion of a short aluminium billet through straight-sided dies is presented and characteristic features of the formation of dead metal zone are observed.     

Adaptive finite element remeshing in a large deformation analysis of metal powder forming

In this paper, a general framework for the finite element simulation of powder forming processes is presented. A large displacement formulation, based on a total and updated Lagrangian formulation and an adaptive finite element strategy based on error estimates and automatic remeshing techniques are utilized. To describe the constitutive model of the highly non‐linear behaviour of powder materials, an elliptical cap model based on a hardening rule to define the dependence of the yield surface on the degree of plastic straining is applied. The interfacial behaviour between the die and powder is modelled by using a plasticity theory of friction in the context of an interface element formulation. Finally, the powder behaviour during the compaction of a set of complex shapes are analysed numerically. The simulation of the deformation is shown as well as the distribution of relative density contours at different time stages. The results clearly indicate that the algorithm makes it possible to simulate the powder forming problems efficiently and automatically. Copyright © 1999 John Wiley & Sons, Ltd.     

2D adaptive mesh methodology for the simulation of metal forming processes with damage

In this work, a fully adaptive 2D numerical methodology is proposed in order to simulate with accuracy various metal forming processes. The methodology is based on fully coupled advanced finite strain constitutive equations accounting for the main physical phenomena such as large plastic deformation, non-linear isotropic and kinematic hardening, ductile isotropic damage and contact with friction. The adaptivity concerns the space discretization using FEM as well as the applied loading sequences. Mesh size distribution is based on various error indicators making use of the hessian of the plastic strain rate combined with a specific damage error function and a specific local curvature error function evaluated at contact boundaries. 2D mesh size can be refined or coarsened when necessary according to these error indicators. Particularely, the smallest size is found to be inside the zones where the damage is highly active. The applied loading paths are also adaptively decomposed into various sequences depending on both number and size of the fully damaged elements. The adaptive procedure is validated through various sheet and bulk metal forming examples. In this paper, a plane stress tensile test, an axisymmetric blanking process of two materials with different ductilities and a cold extrusion process are presented.     

Three-dimensional finite element contact algorithm for metal forming

This work presents a three-dimensional rigid plastic finite element formulation. The workpiece is discretized with eight node hexahedral isoparametric elements. Friction is included in the formulation by means of a shear stress depending on the relative velocity between the workpiece and the tool. Special attention is given to the contact problems, and a three-dimensional contact algorithm based on a discretization of the tool surface with triangular elements is presented. Finally, some selected examples are solved, in order to show the capabilities of the formulation.     

Efficient implicit finite element analysis of sheet forming processes

The computation time for implicit finite element analyses tends to increase disproportionally with increasing problem size. This is due to the repeated solution of linear sets of equations, if direct solvers are used. By using iterative linear equation solvers the total analysis time can be reduced for large systems. For plate or shell element models, however, the condition of the matrix is so ill that iterative solvers do not reach the huge time‐savings that are realized with solid elements. By introducing inertial effects into the implicit finite element code the condition number can be improved and iterative solvers perform much better. An additional advantage is that the inertial effects stabilize the Newton–Raphson iterations. This also applies to quasi‐static processes, for which the inertial effects finally do not affect the results. The presented method can readily be implemented in existing implicit finite element codes. Industrial size deep drawing simulations are executed to investigate the performance of the recommended strategy. It is concluded that the computation time is decreased by a factor of 5 to 10. Copyright © 2003 John Wiley & Sons, Ltd.     

Adaptive mesh refinement processes for finite element solutions

The nature of adaptive processes is reviewed using as an example a specific finite element problem. Several possible formulations for the objective of mesh refinement processes are given. For the most natural of these objectives the A*-algorithms of artificial intelligence turn out to provide a solution process which is known to be optimal in a certain sense. But practically, there is insufficient information and these processes tend to be inefficient. On the other hand, if the objective is replaced by a strictly local objective based on Pareto-optimality, the error estimates of the resulting mesh sequence are shown to exhibit the order of convergence which is known to be best possible for the type of elements used.     

Analysis of superplastic metal forming by a finite element method

A finite element velocity method for analysing the superplastic sheet metal forming process is presented. This method is developed from the principle of virtual work and is based on the use of isoparametric continuum elements. The large inelastic deformation of the superplastic material is modelled as the behaviour of an incompressible non-linear viscous flow material. The contact and friction problem is solved by using the compatibility load step method, which is an extension of an earlier work. The finite element method is applied to selected problems to illustrate the applicability of the solution procedure.     

A particle finite element method for analysis of industrial forming processes

We present a generalized Lagrangian formulation for analysis of industrial forming processes involving thermally coupled interactions between deformable continua. The governing equations for the deformable bodies are written in a unified manner that holds both for fluids and solids. The success of the formulation lays on a residual-based expression of the mass conservation equation obtained using the finite calculus method that provides the necessary stability for quasi/fully incompressible situations. The governing equations are discretized with the FEM via a mixed formulation using simplicial elements with equal linear interpolation for the velocities, the pressure and the temperature. The merits of the formulation are demonstrated in the solution of 2D and 3D thermally-coupled forming processes using the particle finite element method.     

A finite element model for thermomechanical analysis of sheet metal forming

A thermal model based on explicit time integration is developed and implemented into the explicit finite element code DYNA3D to model simultaneous forming and quenching of thin‐walled structures. A staggered approach is used for coupling the thermal and mechanical analysis, wherein each analysis is performed with different time step sizes. The implementation includes a thermal shell element with linear temperature approximation in the plane and quadratic in the thickness direction, and contact heat transfer. The material behaviour is described by a temperature‐dependent elastic–plastic model with a non‐linear isotropic hardening law. Transformation plasticity is included in the model. Examples are presented to validate and evaluate the proposed model. The model is evaluated by comparison with a one‐sided forming and quenching experiment. Copyright © 2004 John Wiley & Sons, Ltd.     

A finite element analysis of damage propagation during metal forming process

In this paper damage propagation during metal forming process is investigated with the concept of continuum damage mechanics. An isotropic damage model based on the theory of materials of type N is adopted to describe the damage process of a ductile material with large elasto-viscoplastic deformation. To solve the finite elasto-viscoplasticity problem, a reasonable kinematic strain measure for largely deformed solids is used and the damage constitutive equations based on thermodynamical framework are developed. The stiffness degradation of the loaded material is chosen as a damage measure. An extended interior penalty method is used to impose the contact condition on the boundary. The highly nonlinear equilibrium equations are reduced to the incremental weak form and approximated by the total Lagrangian finite element method. The displacement control method along with the modified Riks' continuation technique based on displacement parameter is used to solve the incremental iterative equations. As numerical examples, upsetting, backward extrusion and punch problems are simulated and the results of damage propagation and J₂ stress contours with and without damage are presented. For punch problems, spring back and residual stresses are also presented.     

Investigation of anisotropy problems in sheet metal forming using finite element method

This paper discusses the results of the numerical study of rectangular cup drawing of steel sheets using finite element methods. To be able to verify the results of the numerical solutions, an experimental study was done where the material behavior under deformation was analyzed. A 3D parametric finite element (FE) model was built using the commercial FE-package ABAQUS/Standard. ABAQUS allows analyzing physical models of real processes putting special emphasis on geometrical non-linearities caused by large deformations, material non-linearities and complex friction conditions. Friction properties of the deep drawing quality steel sheet were determined by using the pin-on-disc tribometer. The results show that the friction coefficient depends on the measured angle from the rolling direction and corresponds to the surface topography. A quadratic Hill anisotropic yield criterion was compared with von Mises yield criterion having isotropic hardening. The sensitivity of constitutive laws to the initial data characterizing material behavior is also presented. It is found out that plastic anisotropy of the matrix in ductile sheet metal has influence on deformation behavior of the material. When the material and friction anisotropy are taken into account in the finite element analysis, this approach gives better approximate numerical results for real processes.     

Finite element modelling of the effect of non-metallic inclusions in metal forming processes

The presence of non-metallic inclusions can result in material failure during the metal forming process, or lead to a serious deterioration of the quality of the final product. Understanding the effects of inclusions during metal forming is therefore an important step towards predicting the behaviour of inclusions and subsequently minimising their consequences. To achieve this understanding the authors incorporated non-metallic inclusions into a finite element (FE) simulation of metal forming. The chosen metal forming process was rod drawing, the chosen inclusion material aluminium oxide (Al₂O₃) and the chosen inclusion shape spherical. Real rod drawing experiments were also designed with Al₂O₃ spheres embedded in a steel rod in order to compare experimental and simulated results. Specifically, from the experiments carried out the changes of the rod around the inclusion were investigated and the findings compared with the finite element simulation results of an equivalent model. The FE simulation of the experiments considered specifically the fracturing of brittle inclusions. A concept allowing the fracturing of brittle inclusions by means of finite element method is described. Experimental results from fourpoint bending tests, and tensile tests, for Al₂O₃ ceramic bodies were used to calibrate the simulation. Further experiments involved the crushing of Al₂O₃ spheres where the force necessary to achieve crushing was measured and compared with the results of the calibrated FE simulation. It is demonstrated that the intended FE method for the simulation of brittle fracture of inclusions can be used with good accuracy.     

A multi-layer triangular membrane finite element for the forming simulation of laminated composites

Continuous fibre reinforced thermoplastics offer a cost reduction compared to thermosets due to promising fast production methods like diaphragm forming and rubber pressing. Forming experiments of pre-consolidated four-layer 8H satin weave PPS laminates on a dome geometry demonstrated that inter-ply friction is a dominant parameter in forming doubly curved components. Therefore, simulations of this process as sequentially draping the individual layers are invalid. A multi-layer triangular membrane finite element has been developed for efficient simulation of laminated composite forming processes with only one element in the thickness direction. Contact logic between the individual plies is avoided. The simulations were validated by comparison to the experiments mentioned and agree well. The multi-layer membrane element has shown to be capable of predicting the material instabilities during forming. They appeared to be unsuited for realistic wrinkling simulations due to their lack of a bending stiffness.