Simulation of sheet metal forming using explicit finite element techniques: effect of material and forming characteristics

Mamalis, A.G.; Manolakos, D.E.; Baldoukas, A.K.

doi:10.1016/s0924-0136(97)00137-4

Cited by 20 publications

(14 citation statements)

References 2 publications

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“…Many researchers investigated the rectangular/square-cup deep-drawing process experimentally and numerically. A. G. Mamalis et al 1 investigated the effect of material and forming characteristics on the simulation of the deep drawing of square cups by using the explicit non-linear finite-element code DYNA-3D. They considered the effect of material density, punch velocity and friction coefficient.…”

Section: Introductionmentioning

confidence: 99%

Modeling the deep drawing of an AISI 304 stainless-steel rectangular cup using the finite-element method and an experimental validation

Şener¹,

Kurtaran²

2016

Mater. Tehnol.

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In this paper the deep drawing of a rectangular cup from AISI 304 stainless steel sheet was investigated numerically and experimentally. The finite-element method was used for computer modeling of the deep-drawing process. The thickness distribution predicted from the finite-element analysis was compared with experimental measurements. It was observed that the numerical results agree well with the experimental values. The minimum thickness was observed at the punch radius in both the simulation and experiment. Keywords: deep drawing, rectangular cup, finite element, stainless steel V~lanku je bil numeri~no in eksperimentalno preiskovan globoki vlek pravokotne~a{e iz plo~evine iz nerjavnega jekla AISI 304. Za ra~unalni{ko modeliranje procesa globokega vleka je bila uporabljena metoda kon~nih elementov. Iz analize kon~nih elementov napovedana razporeditev debeline je bila primerjana z eksperimentalnimi meritvami. Preiskava je pokazala, da se numeri~ni rezultati dobro ujemajo z eksperimentalnimi vrednostmi. Najmanj{a debelina je bila opa`ena na radiusu pesti~a, tako pri simulaciji kot tudi pri eksperimentu.

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Section: Introductionmentioning

confidence: 99%

Modeling the deep drawing of an AISI 304 stainless-steel rectangular cup using the finite-element method and an experimental validation

Şener¹,

Kurtaran²

2016

Mater. Tehnol.

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“…Simulations of sheet metal forming require a relatively large end time since the velocity of the punch can be as low as 20 mm/s (Mamalis et al, 1997). The implict numerical method has difficulty converging at a solution when non-linear materials, large deformation and nonsmooth contacts are involved whereas the explicit numerical method does not have difficulty with these.…”

Section: The Implicit Methods and The Explicit Methodsmentioning

confidence: 99%

“…This benchmark involved replicating an experimental study conducted by Mamalis et al (1997) which was to simulate sheet metal forming at punch velocities 10 4 higher than the experimental punch speeds and decreasing the density by 10 3 in order to decrease the dynamic effects caused by using such high punch velocities. The punch velocity was increased to reduce the end time of the simulation and the density was decreased in order to minimise the high dynamic effects introduced by simulating a punch velocity 10 4 higher than the actual experimental punch velocity.…”

Section: Sheet Metal Formingmentioning

confidence: 99%

“…An isotropic hardening model was used for this benchmark and it was found that the experimental radial, hoop and thickness strains produced by Mamalis et al (1997) …”

Section: Sheet Metal Formingmentioning

confidence: 99%

“…This allowed for the mass of the punch to be estimated and from there assuming a height of 45 mm, the wall thickness could be calculated. The chosen material for the blank was 'Galvo 1' (Mamalis, 1997). The mechanical properties for this material can be found in the table below.…”

Section: B5 Friction Between Two Surfacesmentioning

confidence: 99%

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Explicit finite element analysis of high speed piston impacts

Yusuf¹

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The University of Queensland operates three large scale free-piston drivers which consists of the T4, X2 and X3 facilities. These facilities are designed for the worst case scenarios based on conservative analytical impact mechanics, in terms of avoiding catastrophic piston impacts. However, these do not accurately predict the mechanical response for complex real geometry in the event of a piston impact.In 2009, there was a high speed impact of a heavy piston that rendered the facility inoperable for two months. Repeated attempts were made to relieve enough stress in the plastically deformed piston to dislodge it from the compression tube. This impact reiterated the potential damage that can be caused by incorrect operation of the free-piston drivers and revealed that there was no structured methodology to estimate the condition of the facility to inform the repair procedure.In this study, the AUTODYN solver was used to investigate three main explicit structural analysis problems including recreating the 2009 T4 high speed piston impact, perfoming a transient stress analysis of the peak pressure loadings acting on X2's lightweight piston using high strain rate material data and analysing the buffer for the X3 facility.The approach to this study involved testing the solver's ability to capture the physical mechanisms involved during a high speed piston impact. An axisymmetric analysis of T4 shot 10509 was later developed where the numerical results were compared to observational comments of the facility made by the technician following the repair job. This approach to using an axisymmetric model was also used to analyse the peak pressure loadings acting on the X2 piston and the results from this were validated against a static structural analysis. An axisymmetric model of the X3 buffer was developed and this was validated against a 3D model. This study has shown that the AUTODYN solver can be used to model high speed piston impacts with relative confidence. Furthermore, there was enough evidence to show that the numerical recreation of T4 shot 10509 did agree with the technician's observations following T4 shot 10509. This allowed for the response of the facility at higher impact speeds and with varying material properties to be investigated. The transient analysis conducted for the X2 lightweight piston agreed closely with the static structural analysis conducted prior. Since the X3 lightweight piston was made out of similar materials to the X2 piston, this validated the material data used for the X3 piston. It was also discovered that the nylon studs in the X3 facility would not likely fracture from an impact speed of 30 m/s by the X3 lightweight piston. This quantification of safe impact speeds for the X3 buffer was deemed important following the development of new driver operating conditons for the X3 facility.ii Acknowledgements Foremost, I would like to thank my supervisor Dr Gildfind for his continued support throughout the year, and faith in my ability to overcome all obstacles that got in my way....

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Blank optimization for sheet metal forming using multi-step finite element simulations

Wang

Goel

Yang

et al. 2008

Int J Adv Manuf Technol

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Simulation of sheet metal forming using explicit finite element techniques: effect of material and forming characteristics

Cited by 20 publications

References 2 publications

Modeling the deep drawing of an AISI 304 stainless-steel rectangular cup using the finite-element method and an experimental validation

Modeling the deep drawing of an AISI 304 stainless-steel rectangular cup using the finite-element method and an experimental validation

Explicit finite element analysis of high speed piston impacts

Blank optimization for sheet metal forming using multi-step finite element simulations

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