Wrinkling criteria in sheet metal forming for single sided contact situation and its application

The general wrinkling theory based on the rate formulation of the principle of virtual work has been applied in a number of studies on wrinkling during sheet metal forming. No contact with the die was allowed. In this study it is shown that with the right choice of wrinkling modes, the theory can also be used for contact situations. Furthermore, loads normal to the sheet can be taken into account. Therefore, the wrinkling theory has a larger area of application then it was previously considere

Equivalent drawbead model in finite element simulations

In 3D simulations of the deep drawing process the drawbead geometries are seldom included. Therefore equivalent drawbeads are used. In order to investigate the drawbead behaviour a 2D plane strain finite element model was used. For verification of this model experiments were performed. The analyses showed that not only the restraining force should be applied but also the strain changes. The effects of the restraining force and the strain change were implemented in an equivalent drawbead. The effect of using the equivalent drawbead is demonstrated with a few example

Wrinkling prediction in sheet metal forming and experimental verification

In this work, the analysis of Hutchinson and Neale is used for wrinkling prediction. Under a number of assumptions, limitations and simplifications a wrinkling criterion with some restrictive applicability, is obtained. Unfortunately, Hutchinson analysis is limited to regions of the sheet that are free of any contact. When contact is taken into account the problem is further complicated. Consequently, a local indicator based on the change of curvatures under compressive stresses is developed. Both wrinkling indicators are used to drive the adaptive mesh refinement in order to be able to accurately spot wrinkling. The numerical results will be compared to those obtained through experimental testing. A number of hemispherical product samples have been used with various blank holder forces and drawn to different depths to capture the onset of wrinkling, its mode and locatio

3D FEM Simulations of a shape rolling process

A finite element model has been developed for the simulation of the shape rolling of stator\ud vanes. These simulations should support the design of rolling tools for new vane types. For the time being\ud only straight vanes (vanes with a constant cross-section over the length) are studied. In that case the rolling\ud process can be considered stationary and an ALE formulation is suitable to calculate the steady state. Results\ud of simulations and experiments for a symmetrical straight vane are presente

Optimizing the Post Sandvik Nanoflex material model using inverse optimization and the finite element method

This article describes an inverse optimization method for the Sandvik Nanoflex steel in cold forming\ud processes. The optimization revolves around measured samples and calculations using the Finite Element\ud Method. Sandvik Nanoflex is part of the group of meta-stable stainless steels. These materials are characterized\ud by a good corrosion resistance, high strength, good formability and crack resistance. In addition, Sandvik\ud Nanoflex has a strain-induced transformation and, depending on austenising conditions and chemical composition,\ud a stress-assisted transformation can occur. The martensite phase of this material shows a substantial aging\ud response. The inverse optimization is a sub-category of the optimization techniques. The inverse optimization\ud method uses a top down approach, as the name implies. The starting point is a prototype state where the current\ud state is to converge on. In our experiment the test specimen is used as prototype and a calculation result as\ud current state. The calculation is then adapted so that the result converges towards the test example. An iterative\ud numerical optimization algorithm controls the adaptation. For the inverse optimization method two parameters\ud are defined: shape of the product and martensite profile. These parameters are extracted from both calculation\ud and test specimen, using Fourier analysis and integrals. An optimization parameter is then formulated from\ud the extracted parameters. The method uses this optimization parameter to increase the accuracy of ”The Post”\ud material model for Sandvik Nanoflex. [1] The article will describe a method to optimize material models, using\ud a combination practical experiments, Finite Element Method and parameter extraction

The implementation of the vegter yield criterion and a physically based hardening rule in finite elements

A new material description for sheet metal forming using Finite Elements has been developed. The description consists of a yield criterion and a hardening rule. In contrast to most former criteria the new criterion is based on multi-axial stress states. The yield criterion is extended with a physically based hardening rule, in which the flow stress depends on the strain and strain rate. A Limiting Dome Height test is used to examine the material description