Abstract
Most of sheet metal forming processes comprise intermediate trimming operations to remove superfluous material. These operations are required for subsequent forming operations. On the other hand, the springback is strongly influenced by the trimming operations that change the part stiffness and the stress field. From the numerical point of view, this involves the geometrical trimming of the finite element mesh and subsequent remapping of the state variables. This study presents a remapping method based on Dual Kriging interpolation, specifically developed for hexahedral finite elements, which has been implemented in DD3TRIM in-house code. Its performance is compared with the one of the Incremental Volumetric Remapping method, using the split-ring test to highlight their advantages and limitations. The numerical simulation of the forming processes is performed with DD3IMP finite element solver.
Highlights
The finite element simulation of multi-stage sheet metal forming processes requires the modification of the blank geometry, which is the consequence of trimming operations
This study presents and compares two distinct remapping methods for finite element meshes composed by linear hexahedral elements, namely the Incremental Volumetric Remapping (IVR) [5] and the Dual Kriging (DK) [6]
Both methods were implemented in the in-house code DD3TRIM, which was developed to perform trimming and remapping operations involved in the multi-stage sheet metal forming processes
Summary
The finite element simulation of multi-stage sheet metal forming processes requires the modification of the blank geometry, which is the consequence of trimming operations. Some remapping procedure is required to transfer the state variables from the old mesh to the new one, including the ones evaluated at the integration points, within each finite element [1]. This study presents and compares two distinct remapping methods for finite element meshes composed by linear hexahedral elements, namely the Incremental Volumetric Remapping (IVR) [5] and the Dual Kriging (DK) [6]. Both methods were implemented in the in-house code DD3TRIM, which was developed to perform trimming and remapping operations involved in the multi-stage sheet metal forming processes. The IVR and the DK methods are described in detail, where the old and the new finite element meshes are denoted by donor and target mesh, respectively [2,7]
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