Efficient implicit FEM simulation of sheet metal forming

For the simulation of industrial sheet forming processes, the time discretisation is\ud one of the important factors that determine the accuracy and efficiency of the algorithm. For\ud relatively small models, the implicit time integration method is preferred, because of its inherent\ud equilibrium check. For large models, the computation time becomes prohibitively large and, in\ud practice, often explicit methods are used. In this contribution a strategy is presented that enables\ud the application of implicit finite element simulations for large scale sheet forming analysis.\ud Iterative linear equation solvers are commonly considered unsuitable for shell element models.\ud The condition number of the stiffness matrix is usually very poor and the extreme reduction\ud of CPU time that is obtained in 3D bulk simulations is not reached in sheet forming simulations.\ud Adding mass in an implicit time integration method has a beneficial effect on the condition number.\ud If mass scaling is used—like in explicit methods—iterative linear equation solvers can lead\ud to very efficient implicit time integration methods, without restriction to a critical time step and\ud with control of the equilibrium error in every increment. Time savings of a factor of 10 and more\ud can easily be reached, compared to the use of conventional direct solvers.\ud

The management of intelligence-assisted finite element analysis technology

Artificial Intelligence (AI) approaches to Finite Element Analysis (FEA), have had tentative degrees of success over the last few years and some authors have argued that effective FEA can help in the manufacture reliability and safety aspects of engineered artefacts. The author of this paper reviews how such AI techniques have been applied and in this light, the author then uses a Fuzzy Cognitive Mapping (FCM), to develop a framework for the management of intelligence-assisted FEA

Computational methods and software systems for dynamics and control of large space structures

Two key areas of crucial importance to the computer-based simulation of large space structures are discussed. The first area involves multibody dynamics (MBD) of flexible space structures, with applications directed to deployment, construction, and maneuvering. The second area deals with advanced software systems, with emphasis on parallel processing. The latest research thrust in the second area involves massively parallel computers

Drape optimization in woven composites manufacture.

This paper addresses the optimisation of forming in manufacturing of composites. A simplified finite element model of draping is developed and implemented. The model incorporates the non-linear shear response of textiles and wrinkling due to buckling of tows. The model is validated against experimental results and it is concluded that it reproduces successfully the most important features of the process. The simple character of the model results in low computational times that allow its use within an optimisation procedure. A genetic algorithm is used to solve the optimisation problem of minimising the wrinkling in the formed component by selecting a suitable holding force distribution. The effect of regularisation is investigated and the L-curve is used to select a regularisation parameter value. Optimised designs resulting from the inversion procedure have significantly lower wrinkling than uniform holding force profiles, while regularisation allows force gradients to be kept relatively low so that suggested process designs are feasible

Advanced interface modelling for 2D shell & 3D continuum problems

This work is motivated by the need for an efficient yet accurate approach for static and dynamic contact analysis of large-scale structures which can a) capture the optimum con- tact position with a moderate number of contact elements, and b) enable across-partition adaptive contact analysis within a parallel processing environment. In addressing these two issues, a novel adaptive node-to-surface contact approach is proposed to discretise the contact boundaries and to trace the evolution of contact locations. Contact search is a demanding process that can become quite complicated for certain types of problem. In this work, an efficient and robust contact search method is proposed, which can a) locally track the master facet of a given slave node despite the appearance of highly non-smooth contact surface, including surfaces with concave/convex regions or with distinct boundaries as well as reversible normals, and b) globally reallocate the master-slave contact pairs based on the penetration state without an expensive global search, providing an effective adaptive contact approach. A dual-interface-based domain decomposition method emphasising across-partition con- tact coupling is proposed. A pair of fully decomposed node-to-surface contact element are proposed to discretise the across-partition contact boundaries. The assumption of small incremental displacements is adopted, which a) avoids the excessive coupling between the decomposed master and slave, b) reduces significantly the communication overhead, and c) facilitates a flexible across-partition adaptive analysis. This strategy is found to provide good results for a sufficiently small time- or load-step, and it also facilitates mix-dimensional contact simulation. Another interest in current thesis is the inaccuracy in non-smooth plates modelled us- ing 2D displacement-based shell elements. In this work the dominant factor causing the inaccuracy is recognised as the incompatible tangential rotations on the two sides of the in- tersection. A 3-noded coupling element is introduced to impose a continuous constraint to couple the incompatible rotations. The significance of the discontinuity in the shell-based folded structure and the effectiveness of the coupling element is demonstrated through numerical studies comparing shell-based models to high fidelity solid-based models.Open Acces

An explicit dynamics GPU structural solver for thin shell finite elements

With the availability of user oriented software tools, dedicated architectures, such as the parallel computing platform and programming model CUDA (Compute Unified Device Architecture) released by NVIDIA, one of the main producers of graphics cards, and of improved, highly performing GPU (Graphics Processing Unit) boards, GPGPU (General Purpose programming on GPU) is attracting increasing interest in the engineering community, for the development of analysis tools suitable to be used in validation/ verification and virtual reality applications. For their inherent explicit and decoupled structure, explicit dynamics finite element formulations appear to be particularly attractive for implementations on hybrid CPU/GPU or pure GPU architectures. The issue of an optimized, double-precision finite element GPU implementation of an explicit dynamics finite element solver for elastic shell problems in small strains and large displacements and rotations, using unstructured meshes, is here addressed. The conceptual difference between a GPU implementation directly adapted from a standard CPU approach and a new optimized formulation, specifically conceived for GPUs, is discussed and comparatively assessed. It is shown that a speedup factor of about 5 can be achieved by an optimized algorithm reformulation and careful memory management. A speedup of more than 40 is achieved with respect of state-of-the art commercial codes running on CPU, obtaining real-time simulations in some cases, on commodity hardware. When a last generation GPU board is used, it is shown that a problem with more than 16 millions degrees of freedom can be solved in just few hours of computing time, opening the way to virtualization approaches for real large scale engineering problems

Finite element analysis of laminated plates and shells, volume 1

The finite element method is used to investigate the static behavior of laminated composite flat plates and cylindrical shells. The analysis incorporates the effects of transverse shear deformation in each layer through the assumption that the normals to the undeformed layer midsurface remain straight but need not be normal to the mid-surface after deformation. A digital computer program was developed to perform the required computations. The program includes a very efficient equation solution code which permits the analysis of large size problems. The method is applied to the problem of stretching and bending of a perforated curved plate