Final deformation of the sheet after springback obtained in the simulation. The triangular element mesh of the deformed sheet is shown.
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Figure The analysis comprised two parts, namely, simulation of the stamping of a S-rail sheet component and springback computations once the stamping tools are removed. The tools are treated as rigid bodies. Explicit and implicit simulations are considered as different curves. The top surface of the sheet does not remain plane due to some instability due to the low blank holder force used.
Simulations results compare very well with experimental values. The outputs of the simulation have been translated into graphical plots indicating the quality of the stamping process and the risk of failure in the different zones of the panel. This helps designers for taking decisions on the adequacy of the stamping process and for introducing changes on the design of the stamping tools dies, punch, blankholders, etc. Lateral panel of an automotive.
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Finite element mesh of EBST1 triangles used for the simulation. In the PFEM nodes are considered as lagrangian particles which move under external or internal forces. A mesh connects the nodes at each time step defining the computational domain where the equations of continuum mechanics are solved with the standard FEM. The PFEM has a big potential for the analysis of bulk forming processes involving very large deformations of deformable continua both fluids and solids , fluid-structure-thermal interactions and multiple frictional contact conditions.
The essential feature of the filling process are well reproduced. The mesh used for the computation at a certain instant is shown in Fig. This ilustrates the fact that the PFEM is, in fact, a blending of particle and finite element procedures. The mesh discretizing the casted region is progressively generated as the mould is filled.
Initially the particles are thrown into the container and mix within the fluid as shown. As time evolves the particles move up towards the surface of the fluid due to their lower density. This example clearly shows the possibilities of the PFEM for analysis of material mixing situations.
We have presented an overview of the advances on the finite element method FEM and on the new particle-finite element method PFEM for industrial metal forming processes. The new stabilized FEM offer many possibilities for analysis of multiphysics bulk forming processes. Also the new rotation-free shell elements are a powerful technique for simulation of sheet metal stamping processes.
The PFEM is particularly suited for simulation of bulk metal forming problems involving coupled fluid-structure interaction, material non linearity and complex frictional contact situations. Circles indicate external and internal free surfaces. This support is gratefully acknowledged.
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Computational plasticity in powder forming processes
Thermo-mechanical analysis of industrial solidification processes. Flores, F. A rotation-free thin shell quadrilateral. Comput Meth Appl Mech Engng.
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A comparison of rotation-free triangular shell elements for unstructured mesh. Kobayashi, S. Thermoviscoplastic analysis of metal forming problems by the finite element method.
Pittman et al. Wiley, Chichester. Idelsohn S. Multi-fluid flows with the PFEM. Third Int. Zienkiewicz, A viscous shell formulation for the analysis of thin sheet metal forming. Agelet, Finite element analysis of sheet metal forming problems using a selective bending membrane formulation. Rotation-free plate and shell triangles. Int J Num Meth Engng. Idelsohn, F. Del Pin and R. Aubry, The Particle finite element method. An overview.
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Flores, Advances in the formulation of the rotation-free basic shell triangle. Rojek, M.
Chiumenti, S. Del Pin, R. Advances in stabilized finite element and particle methods for bulk forming. Flores, L. Neamtu, Enhanced rotation-free basic shell triangle. Applications to sheet metal forming. Owen eds. Rossi, S. Idelsohn, K. Butler, Melting and spread of polymers in fire with the PFEM. Numerical Methods in Engineering 81 8 , Pittman, J. Rojek, J. Tabarraie, A. Thomas, F. Vahdati, M.
Wang, J. Wood, R. Yagewa, G. Published on Dec View Download 3. Electromagnetic Forming of Metal Lecture 03 Actual simulation techniques for forming??
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