Numerical simulation of sheet metal forming: a review

Ablat, Muhammad Ali; Qattawi, Ala

doi:10.1007/s00170-016-9103-5

Cited by 98 publications

(42 citation statements)

References 151 publications

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“…As the mesh generation is random, even when applying fine meshes, the output result will always have small discrete variations, which can lead to noisy data. In this work, the One-At-a-Time (OAT/OFAT) method was used to perform a sensitivity analysis of the cost function [1,23], where the contributions were determined by varying a parameter, while keeping all the others constant. The initial configuration shown in Figure 1 and Control Point 4 were selected for the sensitivity analysis.…”

Section: Number Of Control Points and Sensitivity Analysismentioning

confidence: 99%

“…Industry is increasingly demanding and becoming more competitive. Due to efficiency and cost reduction requirements, numerical simulation has been applied to sheet metal-forming processes since the 1960s [1]. Currently, numerical simulations can accurately replicate the forming process due to the ability to process complex iterative calculus using material properties, surface properties, and process conditions [2].…”

Section: Introductionmentioning

confidence: 99%

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On the Design of Innovative Heterogeneous Sheet Metal Tests Using a Shape Optimization Approach

Andrade‐Campos

Aquino

Martins

et al. 2019

Metals

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The development of full-field measurement methods has enabled a new trend of heterogeneous mechanical tests. The inhomogeneous strain fields retrieved from these tests are being widely used in the calibration of constitutive models for sheet metals. However, today, there is no mechanical test able to characterize the material in a large range of strain states. The aim of this work is to present a heterogeneous mechanical test with an innovative tool/specimen shape, capable of producing rich heterogeneous strain paths and thus providing extensive information on material behavior. The proposed specimen is found using a shape optimization process where an index that evaluates the richness of strain information is used. In this work, the methodology and results are extended to non-specimen geometry dependence and to the non-dependence of the geometry parametrization through the use of the Ritz method for boundary value problems. Different curve models, such as splines, B-splines, and NURBS, are used, and C1 continuity throughout the specimen is guaranteed. Moreover, several deterministic and stochastic optimization methods are used in order to find the method or the combination of methods able to minimize the cost function effectively. Results demonstrated that the solution is dependent on the geometry definition, as well as on the optimization methodology. Nevertheless, the obtained solutions provided a wider spectrum of strain states than standard tests.

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Section: Number Of Control Points and Sensitivity Analysismentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

On the Design of Innovative Heterogeneous Sheet Metal Tests Using a Shape Optimization Approach

Andrade‐Campos

Aquino

Martins

et al. 2019

Metals

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“…For simulation purposes, a high safety factor was added to the load resulting with simulated load of 35 Kg. The fixed end was constrained with fixed displacement boundary condition [58]. The simulation results, shown in Figure 16, identified the locations of the maximum stress as the top and bottom surface of the cylindrical rod at the fixed end in addition to the corners between the plate and the rectangular bar where a huge change in cross section caused stress concentration in that region.…”

Section: Case Studymentioning

confidence: 99%

Design Consideration for Additive Manufacturing: Fused Deposition Modelling

Alafaghani¹,

Qattawi²,

Ablat³

2017

OJAppS

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Additive Manufacturing (AM) technologies have progressed in the past few years and many of them are now capable of producing functional parts instead of mere prototypes. AM provides a multitude of benefits, especially in design freedom. However, it still lacks industrial relevance because of the absence of comprehensive design rules for AM. Although AM is usually advertised as being the solution for all traditional manufacturing design limitations, the fact is that AM only replaces these limitations with a different set of restrictions. To fully exploit the advantages of AM, it is necessary to understand these limitations and consider them early during the design process. The establishment of design considerations in AM enables parts and process optimization. This paper discusses the design considerations that will lead to optimize part quality. Specifically, the work discusses the Fused Deposition Modeling (FDM) due to its common use and availability. These considerations are drawn from literature and from experiments done by the authors. The experiments done by the authors include an investigation for the influence of elevated service temperature on the performance of FDM PLA parts, benchmarking the capability of FDM to print overhangs and bridges without supports, studying the influence of processing parameters over dimensional accuracy, and the effect of processing parameters on the final FDM samples modulus of elasticity. The work presents a case study investigating the correct clearances for FDM parts and finally a redesign for AM case study of a support bracket originally manufactured using traditional manufacturing methods taking into consideration the design considerations discussed in this paper.

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“…The incremental FEM had been employed to forecast the bouncing in this study. (Ablat & Qattawi, 2017) have projected the FDM or Force Descriptor method.…”

Section: Introductionmentioning

confidence: 99%

Art of Single Step Analytical Analysis for Springback Formation in “U” Bending Forming Process

Saravanan*,

Saravanan,

Jeyasimman

et al. 2020

IJITEE

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The formation of the quality of sheet metal had been influenced through spring-back. The exact forecast and directing bouncing were significant. So that the tools are designed for the establishment of sheet metal. Numerous methods had been forecasted for bouncing recompense through alteration of the outline of the tooling. This approach was iterative FEM. In these papers, a systematic method was offered for single-step alteration of the outline of the tooling in channel establishment procedure to recompense the bouncing error. In a limited moment, the outline of the target could be attained through the optimal outline of the die. This establishment is based on these approaches. The set of rules of bouncing recompense through reverse FEM is also summarized. The consequences of the systematic method overlap through those of FEM. The exactness of the attained results was proved through the consequences of the experiment. So that there is the attainment of high exactness.

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Numerical simulation of sheet metal forming: a review

Cited by 98 publications

References 151 publications

On the Design of Innovative Heterogeneous Sheet Metal Tests Using a Shape Optimization Approach

On the Design of Innovative Heterogeneous Sheet Metal Tests Using a Shape Optimization Approach

Design Consideration for Additive Manufacturing: Fused Deposition Modelling

Art of Single Step Analytical Analysis for Springback Formation in “U” Bending Forming Process

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