Abstract
The concept of Industry 4.0 is defined as a common term for technology and the concept of new digital tools to optimize the manufacturing process. Within this framework of modular smart factories, cyber-physical systems monitor physical processes creating a virtual copy of the physical world and making decentralized decisions. This article presents a review of the literature on virtual methods of computer-aided manufacturing processes. Numerical modeling is used to predict stress and temperature distribution, springback, material flow, and prediction of phase transformations, as well as for determining forming forces and the locations of potential wrinkling and cracking. The scope of the review has been limited to the last ten years, with an emphasis on the current state of knowledge. Intelligent production driven by the concept of Industry 4.0 and the demand for high-quality equipment in the aerospace and automotive industries forces the development of manufacturing techniques to progress towards intelligent manufacturing and ecological production. Multi-scale approaches that tend to move from macro- to micro- parameters become very important in numerical optimization programs. The software requirements for optimizing a fully coupled thermo-mechanical microstructure then increase rapidly. The highly advanced simulation programs based on our knowledge of physical and mechanical phenomena occurring in non-homogeneous materials allow a significant acceleration of the introduction of new products and the optimization of existing processes.
Highlights
The implementation of new systems of Computer Aided Engineering (CAE) and products requires a systematic approach to the development and design of technical systems and products
Many customisable product development methodologies have been developed in recent decades, i.e., Autogenetic Design Theory (ADT) [1], Engineering Design [2], Product-Service Systems (PSS) [3], Integrated Product Development (IPD) [4], and the Verein Deutscher Ingenieure (VDI) 2221 guidelines (Figure 1) [5]
Takuda et al [99] have shown that Cockcroft-Latham damage criterion, which integrates the plastic strain and the maximum principal stress, can accurately predict the crack occurrence during sheet metal, and the crack behavior due to tube forming was presented by Ma [100]
Summary
The implementation of new systems of Computer Aided Engineering (CAE) and products requires a systematic approach to the development and design of technical systems and products. Numerical simulation is a complex process that takes into account many independent physical phenomena, such as work hardening, material formability, heat transfer, post-forming microstructure, and the prediction of tool life (Figure 1). Scientific conferences on plastic working allow for the exchange of experiences and views of scientists. The aim of the cyclically organized NUMISHEET and the Numerical Methods for Industrial Forming Processes (NUMIFORM) conferences is to integrate the scientific community and create a platform for building interdisciplinary research teams. NUMIFORM international conference series aim to provide a forum where future directions in the numerical modeling of plastic working processes are discussed by engineers from industry and by scientists. The main numerical approaches analyzed in the context of the modeling of complex phenomena existing in metal forming (Figure 2) include the FEM, BEM, DEM, and meshless methods
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