Plastic dislocation and incompatibility density as indicators for residual stresses

Residual stresses in forming simulations are typically investigated by analyzing the remaining stress state after removing all external loadings. However, the generation of the stress state during forming remains unknown. As a remedy, we use the plastic and elastic dislocation and incompatibility densities - derived from continuum mechanical and differential geometrical considerations - as indicators to track the generation of residual stresses through out a forming operation. Theoretical backgrounds for small and large strain plasticity are highlighted and practical aspects regarding implementation are provided. Two examples demonstrate the functionality of the approach, whereby the plastic incompatibility density in phenomenological, multiplicative large strain plasticity serves as indicator

Case Study on the Influence of Kinematic Hardening within a Parameter-free and Non-invasive Form Finding Approach

Inverse form finding – as a type of shape optimization – aims in determining the optimal preform design of a workpiece for a specific forming process, whereby the desired target geometry is known. Recently, a novel parameter-free and heuristic approach was developed to tackle this nonlinear optimization problem. Benchmark tests already delivered promising results. As a particular note-worthy feature of the approach, a coupling to an arbitrary finite element software is feasible in a non-invasive fashion. The aim of this contribution is to investigate the effect of kinematic hardening and cyclic loading on the convergence behavior of the algorithm

On a recursive formulation for solving inverse form finding problems in isotropic elastoplasticity

Background: Inverse form finding methods allow conceiving the design of functional components in less time and at lower costs than with direct experiments. The deformed configuration of the functional component, the applied forces and boundary conditions are given and the undeformed configuration of this component is sought. Methods: In this paper we present a new recursive formulation for solving inverse form finding problems for isotropic elastoplastic materials, based on an inverse mechanical formulation written in the logarithmic strain space. First, the inverse mechanical formulation is applied to the target deformed configuration of the workpiece with the set of internal variables set to zero. Subsequently a direct mechanical formulation is performed on the resulting undeformed configuration, which will capture the path-dependency in elastoplasticity. The so obtained deformed configuration is furthermore compared with the target deformed configuration of the component. If the difference is negligible, the wanted undeformed configuration of the functional component is obtained. Otherwise the computation of the inverse mechanical formulation is started again with the target deformed configuration and the current state of internal variables obtained at the end of the computed direct formulation. This process is continued until convergence is reached. Results: In our three numerical examples in isotropic elastoplasticity, the convergence was reached after five, six and nine iterations, respectively, when the set of internal variables is initialised to zero at the beginning of the computation. It was also found that when the initial set of internal variables is initialised to zero at the beginning of the computation the convergence was reached after less iterations and less computational time than with other values. Different starting values for the set of internal variables have no influence on the obtained undeformed configuration, if convergence can be achieved. Conclusions: With the presented recursive formulation we are able to find an appropriate undeformed configuration for isotropic elastoplastic materials, when only the deformed configuration, the applied forces and boundary conditions are given. An initial homogeneous set of internal variables equal to zero should be considered for such problems

A non-invasive node-based form finding approach with discretization-independent target configuration

Form finding is used to optimize the shape of a semi-finished product, i.e. the material configuration in a forming process. The geometry of the semi-finished product is adapted so that the computed spatial configuration corresponds to a prescribed target spatial configuration. Differences between these two configurations are iteratively minimized. The algorithm works non-invasively, thus there is a strict separation between the form update and the finite element (FE) forming simulation. This separation allows the use of arbitrary commercial FE-solvers. In particular, there is no need for a modification of the FE forming simulation, only the material configuration is iteratively updated. A new method is introduced to calculate the difference between the target and the computed spatial configuration. Thereby the target mesh is separated from the mesh for the FE forming simulation, which enables a more accurate and independent representation of the target configuration. In addition, the possibility of taking into account manufacturing constraints in the optimization process is presented. The procedure is illustrated for the example of the first stage of a novel two-stage sheet-bulk metal forming process

A novel continuum approach to gradient plasticity based on the complementing concepts of dislocation and disequilibrium densities

A geometrically linear continuum mechanics framework is proposed for gradient plasticity combining ’strain gradients’ and, with a novel approach, ’stress gradients’. Thereby the duality of kinematic and kinetic quantities is exploited in view of the ’div-grad-curl orthogonality’ in continuum field theories. On the one hand the non-integrability of the plastic distortion results in the well-established dislocation density - often denoted as the geometrically-necessary-dislocation (GND) density - that enters the energy storage function. On the other hand - as entirely novel concept introduced in this contribution - the non-equilibrium of the plastic stress results in the disequilibrium density that parameterizes the dual dissipation potential within the convex analysis setting of plasticity. Consequently both, the dislocation density as well as the disequilibrium density contribute in modelling the size-dependent hardening state of a material in a continuum mechanics setting. The novel approach is eventually elucidated in much detail for the specific case of single crystal plasticity

Case study on the influence of kinematic hardening within a parameter-free and non-invasive form finding approach

Inverse form finding – as a type of shape optimization – aims in determining the optimal preform design of a workpiece for a specific forming process, whereby the desired target geometry is known. Recently, a novel parameter-free and heuristic approach was developed to tackle this nonlinear optimization problem. Benchmark tests already delivered promising results. As a particular note-worthy feature of the approach, a coupling to an arbitrary finite element software is feasible in a non-invasive fashion. The aim of this contribution is to investigate the effect of kinematic hardening and cyclic loading on the convergence behavior of the algorithm

Plastic dislocation and incompatibility density as indicators for residual stresses

Residual stresses in forming simulations are typically investigated by analyzing the remaining stress state after removing all external loadings. However, the generation of the stress state during forming remains unknown. As a remedy, we use the plastic and elastic dislocation and incompatibility densities - derived from continuum mechanical and differential geometrical considerations - as indicators to track the generation of residual stresses through out a forming operation. Theoretical backgrounds for small and large strain plasticity are highlighted and practical aspects regarding implementation are provided. Two examples demonstrate the functionality of the approach, whereby the plastic incompatibility density in phenomenological, multiplicative large strain plasticity serves as indicator

Illustration of an improved non-invasive form finding algorithm

Shape optimization is commonly used in various fields of metal forming. Merklein et al. [6] introduced a novel class of forming process, sheet bulk metal forming (SBMF), which is being continuously improved and applied within the collaborative research group TR73. For SBMF, non-invasive form finding is used to optimize the shape of semi-finished products, which is adapted to the forming process a priori, as it is general practice for tailored blanks. The node-based, non-invasive algorithm minimizes the differences between the spatial configuration and the prescribed discretized target configuration by updating the material configuration iteratively up to the optimum semi-finished product geometry

A non-invasive form finding method with application to metal forming

Inverse form finding aims in determining the optimal material configuration of a workpiece for a specific forming process. A gradient- and parameter-free (nodal-based) form finding approach has recently been developed, which can be coupled non-invasively as a black box to arbitrary finite element software. Additionally the algorithm is independent from the constitutive behavior. Consequently, the user has not to struggle with the underlying optimization theory behind. Benchmark tests showed already that the approach works robustly and efficiently. This contribution demonstrates that the optimization algorithm is also applicable to more sophisticated forming processes including orthotropic large strain plasticity, combined hardening and frictional contact. A cup deep drawing process with solid-shell elements and a combined deep drawing and upsetting process to form a functional component with external teeth are investigated