Abstract
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.
Highlights
Metal forming processes are distinguished into sheet and bulk metal forming
Thereby the target mesh is separated from the mesh for the finite element (FE) forming simulation, which enables a more accurate and independent representation of the target configuration
Processes for material pre-distribution are used, see [2]. In this contribution we focus as an example on a two-stage forming process from the family of sheet-bulk metal forming (SBMF) processes
Summary
Metal forming processes are distinguished into sheet and bulk metal forming. This classification results from the prevailing stress state of the respective forming operation. The algorithm projects the spatial difference vector to the material configuration for the form update.
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