Simulation Of Metal Forming Processes By The Finite Element Method Simop I

The numerical simulation of sheet metal forming processes has become an indispensable tool for the design of components and their forming processes. This role was attained due to the huge impact in reducing time to market and the cost of developing new components in industries ranging from automotive to packing, as well as enabling an improved understanding of the deformation mechanisms and their interaction with process parameters. Despite being a consolidated tool, its potential for application continues to be discovered with the continuous need to simulate more complex processes, including the integration of the various processes involved in the production of a sheet metal component and the analysis of in-service behavior. The quest for more robust and sustainable processes has also changed its deterministic character into stochastic to be able to consider the scatter in mechanical properties induced by previous manufacturing processes. Faced with these challenges, this Special Issue presents scientific advances in the development of numerical tools that improve the prediction results for conventional forming process, enable the development of new forming processes, or contribute to the integration of several manufacturing processes, highlighting the growing multidisciplinary characteristic of this field.

The concept of virtual manufacturing has been developed in order to increase the industrial performances, being one of the most ef cient ways of reducing the m- ufacturing times and improving the quality of the products. Numerical simulation of metal forming processes, as a component of the virtual manufacturing process, has a very important contribution to the reduction of the lead time. The nite element method is currently the most widely used numerical procedure for s- ulating sheet metal forming processes. The accuracy of the simulation programs used in industry is in uenced by the constitutive models and the forming limit curves models incorporated in their structure. From the above discussion, we can distinguish a very strong connection between virtual manufacturing as a general concept, ?nite element method as a numerical analysis instrument and constitutive laws,aswellas forming limit curves as a speci city of the sheet metal forming processes. Consequently, the material modeling is strategic when models of reality have to be built. The book gives a synthetic presentation of the research performed in the eld of sheet metal forming simulation during more than 20 years by the members of three international teams: the Research Centre on Sheet Metal Forming—CERTETA (Technical University of Cluj-Napoca, Romania); AutoForm Company from Zürich, Switzerland and VOLVO automotive company from Sweden. The rst chapter presents an overview of different Finite Element (FE) formu- tions used for sheet metal forming simulation, now and in the past.

In diesem Band wird die Entwicklung eines auf der Finite-Elemente-Methode aufbauenden Simulationsverfahrens für die Kalt-, Halbwarm- und Warmmassivumformung beschrieben. Das Verfahren liefert detaillierte Informationen über die plastische Werkstückdeformation sowie Wärmeentstehung und Temperaturausgleich bei Massivumformvorgängen. Die Methode basiert auf dem Markovschen Extremalprinzip und ist auf isotrope, inkompressible Werkstoffe beschränkt. Das starrplastische Fließverhalten wurde mit Hilfe des Stoffgesetzes nach Lévy-Mises erfaßt (bei technischen Vorgängen der Massivumformung können die elastischen und temperaturbedingten Formänderungsanteile gegenüber den plastischen vernachlässigt werden). Die Anwendbarkeit des Simulationsverfahrens wurde an Beispielen zum Kalt- und Warmstauchen von Stahl- und Aluminiumquadern gezeigt. Direkte Vergleiche von berechneten mit experimentellen Untersuchungsergebnissen zeigten eine gute Übereinstimmung. Dazu wurde der zeitliche Temperaturverlauf im Stauchkörper an verschiedenen Stellen meßtechnisch erfaßt und mit den Simulationswerten verglichen. Weitere Vergleiche wurden anhand von Kraft-Weg-Verläufen, Werkstückkonturen und visioplastisch bestimmten Vergleichs-Formänderungsverteilungen durchgeführt.

Written by authorities in the subject, this book provides a complete treatment of metal forming and machining by using the computational techniques FEM, fuzzy set theory and neural networks as modelling tools. The algorithms and solved examples included make this book of value to postgraduates, senior undergraduates, and lecturers and researchers in these fields. Research and development engineers and consultants for the manufacturing industry will also find it of use.