Implementation of finite element analysis for solving the constraints in forming process of large steel parts

Abstract

In recent years, the demand for high-durability parts are rising too much. These challenges are difficult to overcome without an innovative framework based on an accurate database. The problems of high stress generated due to the hard friction and severe crystal dislocation during the forming process need to be solved. High frictional forces between the contact surfaces while forming lead to high sticking between the parts. In this work, forming process of the large sheet metal has been explored based on some parameters like material properties, stress generation, and their effects on the product quality. For this purpose, square sheet metal of 721*721*5 mm is considered, and the product formation through many forming steps was carried out. This work includes adopting some design steps, modeling, and analysis to control some parameters and minimize the generation stresses. The finite element software (ABAQUS/CAE) has been adopted for analyzing this process. In this simulation, the forming process evolution in different steps has been analyzed, and the influence of the effective parameters was performed. As a result, it’s found that the generation stresses are highly concentrated near the fillet zones and proportional to the pressure, and depend on the nature of contact and friction. Simulation results also revealed that the uniform pressure during forming will leads to minimizing the friction and stress generation (5 %) and this will improve the product quality. Also, it’s possible to identify and facilitate many difficulties and evaluate the possibilities before further investing in tooling. It’s concluded that any accurate process like this must depend on some sequence steps like design, modeling, and simulation. Moreover, folding the large surface area needs accurate and adjustable types of equipment.