3D FEM simulations of the rolling of stator vanes, including tool deformation

Tool deformation is an important issue in the shape rolling of stator vanes as it directly influences the thickness of the rolled vane. This means that for the design of an accurate production process the deformation of the tools has to be accounted for. The shape rolling of symmetrical straight vanes has been investigated. Because these vanes have a constant cross-section over the length, this rolling process can be considered as a stationary process. Therefore an ALE formulation is suitable to calculate the steady state. The deformation of the sheet as well as the deformation of the tools have been calculated with the developed finite element model. Some results of these simulations are presented in this paper

Tool deformation during the shape rolling of stator vanes

Tool deformation is an important issue in the shape rolling of stator vanes as it directly\ud influences the thickness of the rolled vane. This means that for the design of an accurate production process\ud the deformation of the tools has to be accounted for. The shape rolling of symmetrical straight vanes has been\ud investigated. This rolling process is considered stationary, because these vanes have a constant cross-section\ud over the length. Therefore an ALE formulation is suitable to calculate the steady state. The deformation of\ud the sheet as well as the deformation of the tools have been calculated with the developed finite element model.\ud Some results of these simulations are presented in this pape

3D FEM Simulation of shape rolling using an ALE method

The shape rolling of stator vanes has been modelled in 3D using the finite\ud element method. Till now only the rolling of straight vanes, which have a constant cross section, is studied. Therefore this rolling process can be considered as a stationary process. Such processes can be described as a flow problem using the Arbitrary Lagrangian Eulerian (ALE) formulation. This makes it possible to follow free surfaces and to adapt the mesh in order to avoid large element distortions, to keep or create refinements were needed. The mesh topology however remains constant during a simulation. Topics of the ALE formulation such as mesh relocation, transfer of state variables etc. will be addressed in the paper. The tools are modelled as deformable bodies, as tool deformation is the most important reason for the deviation of the vane dimensions from the required dimensions. 3D FEM simulations have been carried out of the rolling of a test vane. Some characteristic results, such as material flow, tool deformations, stresses and strains, will be shown

Modelling of ductile failure in metal forming

Damage and fracture are important criteria in the design of products and processes. Damage models can be used to predict ductile failure in metal forming processes. Nonlocal models avoid the mesh dependency problems of local damage models. A nonlocal damage model has been implemented in LSDYNA using the user-subroutines UMAT and UCTRL1. The implemented model will be compared with\ud results obtained with the available option in LS-DYNA to combine *MAT PLASTICITY WITH DAMAGE with *MAT NONLOCAL. Advantages and disadvantages of the different implementations will be discussed. The user nonlocal damage model has been applied to a bending and a blanking process. Results of these simulations will be shown

Finite element model of the guillotining process

Guillotining is a sheet metal cutting process, in which the sheet is cut pro-\ud gressively from one end to the other. Consequently guillotining can be seen as a three-\ud dimensional stationary process. A finite element model is developed for the calculation of the steady state of this process. To be able to handle history dependent material pro-\ud perties and moving free surfaces an Arbitrary Lagrangian Eulerian formulation is used.\ud The position of the crack front is initially modelled and kept �xed during the calculation.\ud The results of a guillotining simulation are shown in this paper

Implementation of an anisotropic damage material model for non-proportional loading

Anisotropic damage for non-proportional loading is incorporated in an implicit finite element code under the framework of continuum damage models, using two different methodologies. Simple simulations are carried out to check the performance of the models. The advantages and drawbacks of both methodologies are discussed briefly