Multi-scale friction modeling for manufacturing processes: The boundary layer regime

This paper presents a multi-scale friction model for largescale forming simulations. A friction framework has been developed including the effect of surface changes due to normal loading and straining the underlying bulk material. A fast and efficient translation from micro to macro modeling, based on stochastic methods, is incorporated to reduce the computational effort. Adhesion and ploughing effects have been accounted for to characterize friction conditions on the micro scale. A discrete model has been adopted which accounts for the formation of contact patches ploughing through the contacting material. To simulate metal forming processes a coupling has been made with an implicit Finite Element code. Simulations on a typical metal formed product shows a distribution of friction values. The modest increase in simulation time, compared to a standard Coulomb-based FE simulation, proves the numerical feasibility of the proposed method

The development of a finite elements based springback compensation tool for sheet metal products

Springback is a major problem in the deep drawing process. When the tools are released after the forming stage, the product springs back due to the action of internal stresses. In many cases the shape deviation is too large and springback compensation is needed: the tools of the deep drawing process are changed so, that the product becomes geometrically accurate after springback. In this paper, two different ways of geometric optimization are presented, the smooth displacement adjustment (SDA) method and the surface controlled overbending (SCO) method. Both methods use results from a finite elements deep drawing simulation for the optimization of the tool shape. The methods are demonstrated on an industrial product. The results are satisfactory, but it is shown that both methods still need to be improved and that the FE simulation needs to become more reliable to allow industrial application

Fast generation of 3D deformable moving surfaces

Dynamic surface modeling is an important subject of geometric modeling due to their extensive applications in engineering design, entertainment and medical visualization. Many deformable objects in the real world are dynamic objects as their shapes change over time. Traditional geometric modeling methods are mainly concerned with static problems, therefore unsuitable for the representation of dynamic objects. Apart from the definition of a dynamic modeling problem, another key issue is how to solve the problem. Because of the complexity of the representations, currently the finite element method or finite difference method is usually used. Their major shortcoming is the excessive computational cost, hence not ideal for applications requiring real-time performance. We propose a representation of dynamic surface modeling with a set of fourth order dynamic partial differential equations (PDEs). To solve these dynamic PDEs accurately and efficiently, we also develop an effective resolution method. This method is further extended to achieve local deformation and produce n-sided patches. It is demonstrated that this new method is almost as fast and accurate as the analytical closed form resolution method and much more efficient and accurate than the numerical methods

A new creep model directly using tabulated test data and implemented in ansys

Nowadays plastics are increasingly used in highly stressed structures in all kinds of constructions. The time dependency, the so-called viscosity, is a crucial part of the material behavior of plastics. A typical form of viscosity is creep. Creep is the increase of deformation under constant load. In the FE-simulation creep behavior is usually described by creep law functions. The commercial software provide many creep law functions depending on time, stress, strain, temperature and multiple material parameters. To run a creep simulation, the user must define all the parameters which requires a certain effort. Curve-fitting procedures might be of help, the results, however, often are not precise enough. For these reasons, we introduce our new creep model doing the similar job as the creep law functions but being able to directly use the tabulated data of the creep tests without curve-fitting procedures. In this paper, we use the model to create a 3D stress-creep strain-time surface based on the tabulated data like isochronous curves, which is represented by bicubically blended Coons patches to provide a good convergence due to their differentiability. This creep model supports strain hardening, which shows more realistic behavior when the load changes significantly during the simulated proces

Analytical approximation of a distorted reflector surface defined by a discrete set of points

Reflector antennas on Earth orbiting spacecrafts generally cannot be described analytically. The reflector surface is subjected to a large temperature fluctuation and gradients, and is thus warped from its true geometrical shape. Aside from distortion by thermal stresses, reflector surfaces are often purposely shaped to minimize phase aberrations and scanning losses. To analyze distorted reflector antennas defined by discrete surface points, a numerical technique must be applied to compute an interpolatory surface passing through a grid of discrete points. In this paper, the distorted reflector surface points are approximated by two analytical components: an undistorted surface component and a surface error component. The undistorted surface component is a best fit paraboloid polynomial for the given set of points and the surface error component is a Fourier series expansion of the deviation of the actual surface points, from the best fit paraboloid. By applying the numerical technique to approximate the surface normals of the distorted reflector surface, the induced surface current can be obtained using physical optics technique. These surface currents are integrated to find the far field radiation pattern