Application of the continuum shell finite element SHB8PS to sheet forming simulation using an extended large strain anisotropic elastic–plastic formulation

http://link.springer.com/article/10.1007%2Fs00419-012-0620-xThis paper proposes an extension of the SHB8PS solid–shell finite element to large strain anisotropic elasto-plasticity, with application to several non-linear benchmark tests including sheet metal forming simulations. This hexahedral linear element has an arbitrary number of integration points distributed along a single line, defining the "thickness" direction; and to control the hourglass modes inherent to this reduced integration, a physical stabilization technique is used. In addition, the assumed strain method is adopted for the elimination of locking. The implementation of the element in Abaqus/Standard via the UEL user subroutine has been assessed through a variety of benchmark problems involving geometric non-linearities, anisotropic plasticity, large deformation and contact. Initially designed for the efficient simulation of elastic–plastic thin structures, the SHB8PS exhibits interesting potentialities for sheet metal forming applications – both in terms of efficiency and accuracy. The element shows good performance on the selected tests, including springback and earing predictions for Numisheet benchmark problems

Investigation of thick sheet AHSS springback in combined bending under tension

In this paper, we investigate the springback behavior of several advanced high-strength sheet steels (TRIP, Dual-Phase, ferrite-bainite) with thicknesses up to 4 mm. Samples were tested by means of the bending-under-tension (BUT) test. The BUT has been extensively applied, in the literature, to relatively thin (1 mm and thinner) sheet metals for automotive applications; the applicability of several guidelines from the literature was investigated in this work in the context of thick advanced high strength steel (AHSS) sheets and using a sample width of 12 mm. The monotonic decrease of springback as back force increased was confirmed for this category of sheet steels, and a general trend for the non-linear influence of the tool radius was observed. With the selected sample width, the effect of the secondary curvature was negligible. Conclusions and simple guidelines are drawn from the analysis with industrial sheet forming applications in mind

Evaluation of a new solid-shell finite element on the simulation of sheet metal forming processes

In this paper, the performance of the solid-shell finite element SHB8PS is assessed in the context of sheet metal forming simulation using anisotropic elastic-plastic behavior models. This finite element technology has been implemented into the commercial implicit finite element code Abaqus/Standard via the UEL subroutine. It consists of an eight-node three-dimensional hexahedron with reduced integration, provided with an arbitrary number of integration points along the thickness direction. The use of an in-plane reduced integration scheme prevents some locking phenomena, resulting in a computationally efficient formulation when compared to conventional 3D solid elements. Another interesting feature lies in the possibility of increasing the number of through-thickness integration points within a single element layer, which enables an accurate description of various phenomena in sheet forming simulations. A general elastic-plastic model has been adopted in the constitutive modeling for sheet forming applications with plastic anisotropy. As an illustrative example, the performance of the element is shown in the earing prediction of a cylindrical cup drawing process.ANR Formef & Région Lorrain

Quadratic solid–shell finite elements for geometrically nonlinear analysis of functionally graded material plates

In the current contribution, prismatic and hexahedral quadratic solid–shell (SHB) finite elements are proposed for the geometrically nonlinear analysis of thin structures made of functionally graded material (FGM). The proposed SHB finite elements are developed within a purely 3D framework, with displacements as the only degrees of freedom. Also, the in-plane reduced-integration technique is combined with the assumed-strain method to alleviate various locking phenomena. Furthermore, an arbitrary number of integration points are placed along a special direction, which represents the thickness. The developed elements are coupled with functionally graded behavior for the modeling of thin FGM plates. To this end, the Young modulus of the FGM plate is assumed to vary gradually in the thickness direction, according to a volume fraction distribution. The resulting formulations are implemented into the quasi-static ABAQUS/Standard finite element software in the framework of large displacements and rotations. Popular nonlinear benchmark problems are considered to assess the performance and accuracy of the proposed SHB elements. Comparisons with reference solutions from the literature demonstrate the good capabilities of the developed SHB elements for the 3D simulation of thin FGM plates

On the implementation of the continuum shell finite element SHB8PS and application to sheet forming simulation

In this contribution, the formulation of the SHB8PS continuum shell finite element is extended to anisotropic elastic-plastic behavior models with combined isotropic-kinematic hardening at large deformations. The resulting element is then implemented into the commercial implicit finite element code Abaqus/Standard via the UEL subroutine. The SHB8PS element is an eight-node, three-dimensional brick with displacements as the only degrees of freedom and a preferential direction called the thickness. A reduced integration scheme is adopted using an arbitrary number of integration points along the thickness direction and only one integration point in the other directions. The hourglass modes due to this reduced integration are controlled using a physical stabilization technique together with an assumed strain method for the elimination of locking. Therefore, the element can be used to model thin structures while providing an accurate description of the various through-thickness phenomena. Its performance is assessed through several applications involving different types of non-linearities: geometric, material and that induced by contact. Particular attention is given to springback prediction for a NUMISHEET benchmark problem.ANR Formef & Région Lorrain

Prediction of strain localization during sheet metal forming using bifurcation analysis and Gurson-type damage

The strain localization phenomenon that may occur during sheet metal forming represents a major cause of defective parts produced in the industry. Several instability criteria have been developed in the literature to predict the occurrence of these instabilities. The proposed work aims to couple a Gurson-type model to the Rice’s localization criterion. The implementation of the modeling is achieved via a user subroutine (Umat) in Abaqus/std using a Runge-Kutta explicit integration scheme. Finally, we show the effectiveness of the proposed coupling for the prediction of the formability of stretched metal sheets.Projet ANR Formef & Région Lorrain

Hardening effects on formability limit prediction based on Gurson-type damage models and bifurcation analysis

In this work, ductility limits of metallic materials, associated with the occurrence of strain localization, are predicted using the GTN damage model coupled with bifurcation theory. The resulting approach is implemented into the finite element code ABAQUS within the framework of large plastic strains and a fully three-dimensional formulation. A parametric study with respect to damage and hardening parameters is conducted in order to identify the most influential material parameters on strain localization. The analysis shows that the damage parameters have a significant impact on the predicted ductility limits, while the effect of hardening parameters on strain localization depends on the choice of void nucleation mechanism

Determination of forming limit diagrams based on ductile damage models and necking criteria

In this paper, forming limit diagrams (FLDs) for an aluminum alloy are predicted through numerical simulations using various localized necking criteria. A comparative study is conducted for the FLDs determined by using the Lemaitre damage approach and those obtained with the modified Gurson–Tvergaard–Needleman (GTN) damage model. To this end, both damage models coupled with elasto-plasticity and accounting for plastic anisotropy have been implemented into the ABAQUS/Explicit software, through the user-defined subroutine VUMAT, within the framework of large plastic strains and a fully three-dimensional formulation. The resulting constitutive frameworks are then combined with four localized necking criteria to predict the limit strains for an AA6016-T4 aluminum alloy. Three of these necking criteria are based on finite element (FE) simulations of the Nakazima deep drawing test with various specimen geometries, while the fourth criterion is based on bifurcation theory. The simulation results reveal that the limit strains predicted by local criteria, which are based on FE simulations of the Nakazima test, are in good agreement with the experiments for a number of strain paths, while those obtained with the bifurcation analysis provide an upper bound to the experimental FLD

Prediction of strain localization using a micromechanics-based damage model: impact of damage and hardening parameters on formability

In this work, ductility limits of metallic materials, associated with the occurrence of strain localization, are predicted using the GTN damage model coupled with bifurcation theory. The resulting approach is implemented into the finite element code ABAQUS within the framework of large plastic strains and a fully three-dimensional formulation. A parametric study with respect to damage and hardening parameters is conducted in order to identify the most influential material parameters on strain localization. The analysis shows that the damage parameters have a significant impact on the predicted ductility limits, while the effect of hardening parameters on strain localization depends on the choice of void nucleation mechanism

Prediction of strain localization during sheet metal forming using bifurcation analysis and Gurson-type damage

The strain localization phenomenon that may occur during sheet metal forming represents a major cause of defective parts produced in the industry. Several instability criteria have been developed in the literature to predict the occurrence of these instabilities. The proposed work aims to couple a Gurson-type model to the Rice’s localization criterion. The implementation of the modeling is achieved via a user subroutine (Umat) in Abaqus/std using a Runge-Kutta explicit integration scheme. Finally, we show the effectiveness of the proposed coupling for the prediction of the formability of stretched metal sheets.Projet ANR Formef & Région Lorrain