Impact of discretization discrepancy in mapping quality depending on mesh displacement and rotation

Abstract

In an effort to reduce prototypes in the industrial manufacturing of sheet metal components and their assembly, numerical simulation is well established. Where each single process transfers into its virtual counterpart to ensure quality assurance, disregarding the influence of their preceding processes. In order to further the accuracy of a virtual process, links between sequenced methods are established to create a process chain considering all influences on a manufactured part in its early design stages. If a finite element solver change occurs within this linkage, it is necessary to transfer and/or transform source mesh bound data to fit the target mesh, if said data may influence any simulation further down the chain. This data transfer, called “mapping”, depends on the utilized allocation and interpolation algorithm. This contribution aims to link the difference in mesh discretization and position to the resulting data quality depending on both meshes as well as various approximation and interpolation procedures. The considered geometry represents a S-shaped profile common in sheet metal forming and subsequent joining whereas the mapped data consist of scalar and tensorial values such as thickness and stresses. It is expected that a large difference in the meshes coupled with certain interpolation methods lead to significant errors during mapping between source- and target-data.