Improvements in FE-analysis of real-life sheet metal forming

An overview will be presented of recent developments concerning the application\ud and development of computer codes for numerical simulation of sheet metal forming\ud processes. In this paper attention is paid to some strategies which are followed to improve the\ud accuracy and to reduce the computation time of a finite element simulation. Special attention\ud will be paid to the mathematical modeling of the material deformation and friction, and the\ud effect of these models on the results of simulations. An equivalent drawbead model is\ud developed which avoids a drastic increase of computation time without significant loss of\ud accuracy. The real geometry of the drawbead is replaced by a line on the tool surface. When\ud an element of the sheet metal passes this drawbead line an additional drawbead restraining\ud force, lift force and a plastic strain are added to that element. A commonly used yield\ud criterion for anisotropic plastic deformation is the Hill yield criterion. This description is not\ud always sufficient to accurately describe the material behavior. This is due to the\ud determination of material parameters by uni-axial tests only. A new yield criterion is\ud proposed, which directly uses the experimental results at multi-axial stress states. The yield\ud criterion is based on the pure shear point, the uni-axial point, the plane strain point and the\ud equi-biaxial point

The influence of curvature on FLC’s of mild steel, (A)HSS and aluminium

In literature the influence of curvature on formability has been reported. This\ud paper shows results for four materials when an FLC is measured with increasing curvature. It shows the FLC increases for sharper curvature most notably with 20 [mm] tool diameter. The increase is negligible on the left hand side, moderate on the right hand side and large on the plane strain axis. It is thought that contact pressure plays a role here and preliminary simulations indicate that this is quite possible

Modelling of Dynamic Strain Aging with a Dislocation-Based Isotropic Hardening Model and Investigation of Orthogonal Loading

Based on experimental results, a dislocation material model describing the dynamic strain aging\ud effect at different temperatures is presented. One and two stage loading tests were performed in\ud order to investigate the influence of the loading direction as well as the temperature influence due\ud to the hardening mechanism. Bergström’s theory of work hardening was used as a basis for the\ud model development regarding the thermal isotropic behavior as well as the Chaboche model to\ud describe the kinematic hardening. Both models were implemented in an in-house FE-Code in\ud order to simulate the real processes. The present paper discusses two hardening mechanisms,\ud where the first part deals with the pure isotropic hardening including dynamic strain aging and the\ud second part involves the influence of the loading direction regarding combined (isotropic and\ud kinematic) hardening behavior

The ALE-method with triangular elements: direct convection of integration point values

The arbitrary Lagrangian-Eulerian (ALE) finite element method is applied to the simulation of forming processes where material is highly deformed. Here, the split formulation is used: a Lagrangian step is done with an implicit finite element formulation, followed by an explicit (purely convective) Eulerian step. The purpose of this study is to investigate the Eulerian step for quadratic triangular elements. To solve the convection equation for integration point values, a new method inspired by Van Leer is constructed. The new method is based on direct convection of integration point values without intervention of nodal point values.\ud The Molenkamp test and a so-called block test were executed to check the performance and stability of the convection scheme. From these tests it is concluded that the new convection scheme shows accurate results. The scheme is extended to an ALE-algorithm. An extrusion process was simulated to test the applicability of the scheme to engineering problems. It is concluded that direct convection of integration point values with the presented algorithm leads to accurate results and that it can be applied to ALE-simulation

Accounting for material scatter in sheet metal forming simulations

Robust design of forming processes is gaining attention throughout the industry. To analyze the robustness of a sheet metal forming process using Finite Element (FE) simulations, an accurate input in terms of parameter variation is required. This paper presents a pragmatic, accurate and economic approach for measuring and modeling one of the main inputs, i.e. material properties and its associated scattering. For the purpose of this research, samples of 41 coils of a forming steel DX54D+Z (EN 10327:2004) from multiple batches have been collected. Fully determining the stochastic material behavior to the required accuracy for precise modeling in FE simulations would involve performing many mechanical experiments. Instead, the present work combines mechanical testing and texture analysis to limit the required effort. Moreover, use is made of the correlations between the material parameters to efficiently model the material property scatter for use in the numerical robustness analysis. The proposed approach is validated by the forming of a series of cup products using the collected material. The observed experimental scatter can be reproduced efficiently using FE simulations, demonstrating the potential of the modeling approach and robustness analysis in general

Material Induced Anisotropic Damage

The anisotropy in damage can be driven by two different phenomena; anisotropic defor-mation state named Load Induced Anisotropic Damage (LIAD) and anisotropic (shape and/or distribution) second phase particles named Material Induced Anisotropic Damage (MIAD). Most anisotropic damage models are based on LIAD. This work puts emphasis on the presence of MIAD in DP600 steel. Scanning Electron Microscopic (SEM) analysis was carried out on undeformed and deformed tensile specimens. The martensite morphology showed anisotropy in size and orientation. Consequently, significant MIAD was observed in the deformed tensile specimens. A through thickness shear failure is observed in the tensile specimen, which is pulled along the rolling direction (RD), whereas a dominant ductile fracture is observed when pulled perpendicular to RD. The Modified Lemaitre’s (ML) anisotropic damage model is improved to account for MIAD in a phenomenological manner. The MIAD parameters are determined from tensile tests carried out in 0o, 45o and 90o to the RD. The formability of DP600 is lower in the RD compared to that in 90o to the RD, due to the phenomenon of MIAD

Inhomogeneous superconductivity induced in a weak ferromagnet

Under certain conditions, the order parameter induced by a superconductor (S) in a ferromagnet (F) can be inhomogeneous and oscillating, which results e.g. in the so-called pi-coupling in S/F/S junctions. In principle, the inhomogeneous state can be induced at T_c as function of the F-layer thickness d_F in S/F bilayers and multilayers, which should result in a dip-like characteristic of T_c(d_F). We show the results of measurements on the S/F system Nb/Cu_{1-x}Ni_x, for Ni-concentrations in the range x = 0.5-0.7, where such effects might be expected. We find that the critical thickness for the occurrence of superconductivity is still relatively high, even for these weak ferromagnets. The resulting dip then is intrinsically shallow and difficult to observe, which explains the lack of a clear signature in the T_c(d_F) data.Comment: 4 pages, 4 figures. To be publishedin Physica C (proceedings of the Second Euroconference on Vortex Matter in Superconductors, Crete, 2001