Abstract
The present work shows the material flow analysis in indentation by the numerical two dimensional Finite Elements (FEM) method and the experimental two-dimensional Digital Image Correlation (DIC) method. To achieve deep indentation without cracking, a ductile material, 99% tin, is used. The results obtained from the DIC technique depend predominantly on the pattern conferred to the samples. Due to the absence of a natural pattern, black and white spray painting is used for greater contrast. The stress-strain curve of the material has been obtained and introduced in the Finite Element simulation code used, DEFORM™, allowing for accurate simulations. Two different 2D models have been used: a plain strain model to obtain the load curve and a plain stress model to evaluate the strain maps on the workpiece surface. The indentation displacement load curve has been compared between the FEM and the experimental results, showing a good correlation. Additionally, the strain maps obtained from the material surface with FEM and DIC are compared in order to validate the numerical model. The Von Mises strain results between both of them present a 10–20% difference. The results show that FEM is a good tool for simulating indentation processes, allowing for the evaluation of the maximum forces and deformations involved in the forming process. Additionally, the non-contact DIC technique shows its potential by measuring the superficial strain maps, validating the FEM results.
Highlights
The indentation process is considered a secondary process due to produced deformations.These deformations are localized, small, and superficial [1,2]
The strain maps obtained from the material surface with Finite Elements (FEM) and Digital Image Correlation (DIC) are compared in order to validate the numerical model
The results show that FEM is a good tool for simulating indentation processes, allowing for the evaluation of the maximum forces and deformations involved in the forming process
Summary
The indentation process is considered a secondary process due to produced deformations. These deformations are localized, small, and superficial [1,2]. New complex functional components are demanded with reduced weight and local strength, for example, for gear elements manufacturing. Localized forming operations are an interesting alternative to conventional machining processes [3]. The IFP are considered an alternative to traditional plastic forming processes. The final shapes are gradually obtained using dies smaller than the workpieces. These processes modify the material thickness in specific areas, causing permanent plastic deformation and change the material properties as well with repetitive impressions
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