Numerical modelling and simulation in sheet metal forming

Abstract

The application of the methods of Computer Aided Engineering in sheet metal forming is looking back for several decades. It covers a wide range of activities from the product design through the process planning and process control including sophisticated methods of modelling and simulation. Among the CAE activities, recently the development of Knowledge Based Systems has become an emerging field. Most of the available Knowledge Based Systems are based on simplified plasticity theory and empirical technological rules. Therefore, they are usually not able to give accurate solutions and reliable predictions for complicated forming processes. In the last two decades, significant progress has been also achieved in the numerical modelling of forming processes. In spite of the enormous development of hardware and software facilities, the exclusive use of numerical modelling still seems to be very time-and cost consuming. Therefore the integration of these two fields has great practical importance. In this paper, the challenges and opportunities of the integration of Knowledge Based Systems and Finite Element Modelling in the process planning of multi-step sheet forming processes will be given.

Numerical study of the solution heat treatment, forming, and in-die quenching (HFQ) process on AA5754

“…However, it is essential that the correct combination of forming parameters, such as temperature, ram speed and blankholding force, are selected. Finite element (FE) process simulations are invaluable for determining and optimizing these parameters, and can reduce the efforts of experimental trials and hence lead times and costs, while ensuring a high quality final part [8][9][10]. The feasibility of new, unconventional metal forming processes can also be assessed by running FE simulations [11,12].…”

Numerical simulation of the effects of the space-variant blank-holder force and geometrical variables in the deep-drawing process

“…In this paper an explicit FEM code, Pam Stamp TM , is used as a tool to simulate the forming process to investigate the effect of the BHF and some geometrical variables. At present, the FEM is the most popular and more accurate method to simulate and explore the efficient control approach of the sheetmetal-forming process, and the commercial package Pam Stamp TM has been employed by many researchers [12][13][14][15]. Six spatial variant BHF settings are adopted to compare their effects on the strain distribution.…”

Sheet Metal Forming Simulation

“…In most forming software packages, Coulomb friction is used to model realistic interface conditions (Tisza, 2004). For instance, the blank shape and all tooling surfaces need to be imported; material properties, including stress-strain curves, parameters for the given yield criteria, forming limit diagram curves, and so on, need to be accurately defined; tooling motions and tooling loads are also necessary to control the process.…”