On the simulation of multi‐stage forming processes: invariance under change of the reference configuration

Abstract

AbstractThe need to change the reference configuration can naturally appear during the numerical simulation of multi‐stage metal forming processes. In the current work, a refined approach to the consideration of previously induced plastic anisotropy is discussed, which is based on such configuration change. The model of finite strain viscoplasticity proposed by Shutov and Kreißig is considered in this study as a practical tool, suitable to capture the evolution of mechanical properties of material during inelastic deformation. The initial plastic anisotropy can be considered within this model by a special choice of initial conditions imposed on the relevant internal variables. A simple transformation law which is based on the isochoric change of the reference configuration is obtained in the current study. This transformation allows to obtain relevant initial conditions with respect to a new reference configuration. Thus, the initial conditions are formulated using the simulation results from the foregoing loading. The advocated approach is exemplified by the numerical simulation of equal channel angular pressing of cylindrical billets. The plastic anisotropy accumulated during a single ECAP pass is estimated using a series of virtual tension tests. These tests were performed on samples cut from processed billet with their gage lengths in different directions. Finally, the impact of the plastic anisotropy on the rotation of the workpiece within the output channel during ECAP is numerically estimated.