Abstract
Treatment of contact between a sheet and tools is one of the most difficult problems to deal with in finite‐element simulations of sheet forming processes. In order to obtain more accurate tool models without increasing the number of elements, this paper describes a new formulation for contact problems using interpolation proposed by Nagata for tool surfaces. A contact search algorithm between sheet nodes and the interpolated tool surfaces was developed and was introduced into the static‐explicit elastoplastic finite‐element method code STAMP3D. Simulations of a square cup deep drawing process with a very coarsely discretized punch model were carried out. The simulated results showed that the proposed algorithm gave the proper drawn shape, demonstrating the validity of the proposed algorithm.
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