Parameter identification of a mechanical ductile damage using Artificial Neural Networks in sheet metal forming.

In this paper, we report on the developed and used of finite element methods, have been developed and used for sheet forming simulations since the 1970s, and have immensely contributed to ensure the success of concurrent design in the manufacturing process of sheets metal. During the forming operation, the Gurson–Tvergaard–Needleman (GTN) model was often employed to evaluate the ductile damage and fracture phenomena. GTN represents one of the most widely used ductile damage model. In this investigation, many experimental tests and finite element model computation are performed to predict the damage evolution in notched tensile specimen of sheet metal using the GTN model. The parameters in the GTN model are calibrated using an Artificial Neural Networks system and the results of the tensile test. In the experimental part, we used an optical measurement instruments in two phases: firstly during the tensile test, a digital image correlation method is applied to determinate the full-field displacements in the specimen surface. Secondly a profile projector is employed to evaluate the localization of deformation (formation of shear band) just before the specimen’s fracture. In the validation parts of this investigation, the experimental results of hydroforming part and Erichsen test are compared with their numerical finite element model taking into account the GTN model. A good correlation was observed between the two approaches

Compensation of a ball end tool trajectory in complex surface milling

This work is consecrated to the minimising of machining errors based on a method for the compensation of the trajectory to be machined in hemispherical milling. This compensation is found to be necessary because of the tool deflection due to the cutting forces. In order to remedy to the machining errors, caused by this deflection, a compensation method has been proposed. The latter is inspired from the mirror method, since the compensated position is going to be determined as being the trajectory reflection, deviated onto the mirror. The advantage of this proposed method is that it takes into account the three deflections dx, dy and dz, respectively to the directions X, Y and Z. After that, two-parallel machinings, separated by a groove and achieved absolutely in the same conditions and with the same tool, are carried out, on the same complex part. The first machining is with compensation, but the second is without compensation. The coordinates of the two obtained surfaces are recorded by a 3D measuring machine. The comparison of the two-surfaces shows the presence of an important correction of the tool trajectory, and reveals a similarity between the part obtained by simulation and the one conceived in CAM

Effect of Ductile Damage Evolution in Sheet Metal Forming: Experimental and Numerical Investigations

The numerical simulation based on the Finite Element Method (FEM) is widely used in academic institutes and in the industry. It is a useful tool to predict many phenomena present in the classical manufacturing forming processes such as necking, fracture, springback, buckling and wrinkling. But, the results of such numerical model depend strongly on the parameters of the constitutive behavior model. In the first part of this work, we focus on the traditional identification of the constitutive law using oriented tensile tests (0°, 45°, and 90° with respect to the rolling direction). A Digital Image Correlation (DIC) method is used in order to measure the displacements on the surface of the specimen and to analyze the necking evolution and the instability along the shear band. Therefore, bulge tests involving a number of die shapes (circular and elliptic) were developed. In a second step, a mixed numerical–experimental method is used for the identification of the plastic behavior of the stainless steel metal sheet. The initial parameters of the inverse identification were extracted from a uniaxial tensile test. The optimization procedure uses a combination of a Monte-Carlo and a Levenberg-Marquardt algorithm. In the second part of this work, according to some results obtained by SEM (Scaning Electron Microscopy) of the crack zones on the tensile specimens, a Gurson Tvergaard Needleman (GTN) ductile model of damage has been selected for the numerical simulations. This model was introduced in order to give informations concerning crack initiations during hydroforming. At the end of the paper, experimental and numerical comparisons of sheet metal forming applications are presented and validate the proposed approach

Analysis of the thinning phenomenon variations in sheet metal forming process

In many manufacturing areas such as the automotive industry (outer panels, inner panels, stiffeners etc...), the packaging industry (petfood containers, beverage cans etc...) and the household appliances industry (housings etc...), the control of the thinning variations in sheet metal forming process is a major point to study in order to ameliorate the final quality of the produced parts. In this framework, several bulge tests have been developed in order to study the thinning phenomenon during sheet metal forming processes. In this presentation, measurement of the thickness of the deformed specimens has been done using the ImageAnalyser software (based on an image analysis technique) developed by the CMAO research group in the LGP. The AISI 304L stainless steel has been selected as the tested material. Both a cylindrical and an elliptical die allowing the analysis of the thickness variation versus the load ratio and the anisotropy of sheet have been used in this work. In a second part of this communication, we present a numerical model based on the Hill 1948 anisotropic material model. The numerical results are discussed and compared with the experiments

Micro-Scale Modeling of Carbon-Fiber Reinforced Thermoplastic Materials

Thin-walled textile-reinforced composite parts possess excellent properties, including lightweight, high specific strength, internal torque and moment resistance which offer opportunities for applications in mass transit and ground transportation. In particular, the composite material is widely used in aerospace and aircraft structure. In order to estimate accurately the parameters of the constitutive law of woven fabric composite, it is recommended to canvass multi-scale modeling approaches: meso, micro and macro. In the present investigation, based on the experimental results established by carrying out observations by Scanning electron microscope (SEM), we developed a micro-scale FEM model of carbon-fiber reinforced thermoplastic using a commercial software ABAQUS. From the SEM cartography, one identified two types of representative volume elementary (RVE): periodic and random distribution of micro-fibers in the yarn. Referring to homogenization method and by applying the limits conditions to the RVE, we have extracted the coefficients of the rigidity matrix of the studied composites. In the last part of this work, we compare the results obtained by random and periodic RVE model of carbon/PPS and we compute the relative error assuming that random model gives the right value

Micro-scale modeling of carbon-fiber reinforced thermoplastic materials

Thin-walled textile-reinforced composite parts possess excellent properties, including lightweight, high specific strength, internal torque and moment resistance which offer opportunities for applications in mass transit and ground transportation. In particular the composite material is widely used in aerospace and aircraft structure. In order to estimate accurately the parameters of the constitutive law of woven fabric composite, it is recommended to canvass multi-scale modeling approaches: meso, micro and macro. In the present investigation, based on the experimental results established by carrying out observations by Scanning electron microscope (SEM), we developed a micro-scale FEM model of carbon-fiber reinforced thermoplastic using a commercial software ABAQUS. From the SEM cartography, one identified two types of representative volume elementary (RVE): periodic and random distribution of micro-fibers in the yarn. Referring to homogenization method and by applying the limits conditions to the RVE, we have extracted the coefficients of the rigidity matrix of the studied composites. In the last part of this work, we compare the results obtained by random and periodic RVE model of carbon/PPS and we compute the relative error assuming that random model gives the right value

Modélisation et simulation des efforts de coupe en fraisage 2.5 axes

L'opération de fraisage est une opération d'usinage fondamentale dans l'industrie pour la production des pièces mécaniques et des moules. La productivité et la précision géométrique de la pièce fabriquée diminuent par les vibrations dues à la discontinuité du contact outil pièce et à la variation de la passe radiale provoquée par le choix de la stratégie d'usinage. L'objectif de cette communication est de proposer un modèle d'efforts de coupe en fraisage 2.5 axes qui tient compte de la variation de la passe radiale. La simulation d'usinage est appliquée sur une poche complexe avec plusieurs stratégies d'usinage afin de déterminer les variations des efforts de coupe et leurs répartitions en fonction des conditions d'usinage

Représentation séparée espace-temps pour des comportements viscoélastiques linaires intégraux

The analysis of materials mechanical behavior involves many computational challenges. In this work, we are addressing the transient simulation of the mechanical behavior when the time of interest is much larger than the characteristic time of the mechanical response. This situation is encountered in many applications, as for example in the simulation of materials aging, or in structural analysis when small-amplitude oscillatory loads are applied during a long period, as it occurs for example when characterizing viscoelastic behaviors by calculating the complex modulus or when addressing fatigue simulations. Moreover, in the case of viscoelastic behaviors, the constitutive equation is many times expressed in an integral form avoiding the necessity of using internal variables, fact that results in an integro-differential model. In order to efficiently simulate such a model, we explore in this work the use of a space-time separated representation.L'analyse du comportement mécanique des matériaux entraîne de nombreuses difficultés du point de vue numérique. Dans ce travail, nous allons nous focaliser sur l'une d'entre elles, celle associée à la simulation transitoire du comportement mécanique quand l'intervalle temporel d'intérêt est substantiellement plus long que le temps caractéristique associé à la réponse mécanique. Cette situation est fréquemment retrouvée dans la caractérisation rhéologique des matériaux viscoélastiques (pour la détermination du module complexe) ainsi que quand on s'attaque à la simulation de la fatigue. De plus, dans le cas des matriaux viscoélastiques, le comportement est généralement décrit par une loi de comportement intégrale qui évite le besoin d'utiliser des variables internes, donnant lieu à un modèle mécanique integro-différentiel. Pour une résolution efficace, nous analysons ici l'utilisation d'une représentation séparée en espace-temps

Numerical and Experimental Investigations on Deep Drawing of G1151 Carbon Fiber Woven Composites

This study proposes to simulate the deep drawing on carbon woven composites in order to reduce the manufacturing cost and waste of composite material during the stamping process, The multi-scale anisotropic approach of woven composite was used to develop a finite element model for simulating the orientation of fibers accurately and predicting the deformation of composite during mechanical tests and forming process. The proposed experimental investigation for bias test and hemispherical deep drawing process is investigated in the G1151 Interlock. The mechanical properties of carbon fiber have great influence on the deformation of carbon fiber composites. In this study, shear angle–displacement curves and shear load–shear angle curves were obtained from a bias extension test. Deep drawing experiments and simulation were conducted, and the shear load–displacement curves under different forming depths and shear angle–displacement curves were obtained. The results showed that the compression and shear between fibers bundles were the main deformation mechanism of carbon fiber woven composite, as well as the maximum shear angle for the composites with G1151 woven fiber was 58°. In addition, during the drawing process, it has been found that the forming depth has a significant influence on the drawing force. It increases rapidly with the increasing of forming depth. In this approach the suitable forming depth deep drawing of the sheet carbon fiber woven composite was approximately 45 mm