Abstract
This paper presents the application of multi scale techniques to the simulation of sheet metal forming using the one-step method. When a blank flows over the die radius, it undergoes a complex cycle of bending and unbending. First, we describe an original model for the prediction of residual plastic deformation and stresses in the blank section. This model, working on a scale about one hundred times smaller than the element size, has been implemented in SIMEX, one-step sheet metal forming simulation code. The utilisation of this multi-scale modeling technique improves greatly the accuracy of the solution. Finally, we discuss the implications of this analysis on the prediction of springback in metal forming.
Highlights
Introduction and state of the artAfter the first industrial applications [1]-[2], sheet metal forming simulation is nowadays part of industrial design processes
We describe the formulations of the code SIMEX as an example of one-step sheet metal forming simulations
The material model implemented in SIMEX follows the plasticity laws of Henki-Mises, which are based on the following hypotheses: The deformation's elastic component can be ignored with respect to the plastic component
Summary
After the first industrial applications [1]-[2], sheet metal forming simulation is nowadays part of industrial design processes. One-step or inverse simulation[3], uses only the final geometry of the stamped part to predict metal deformation. This feature makes it easier to integrate this kind of simulation in the design cycle. This paper describes the theoretical foundation and the implementation in SIMEX of an equivalent model for the cycles of bending and unbending undergone by the blank over the die radius. This development greatly improved the accuracy of SIMEX simulation
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