Simulation of forming processes with local heating of dual phase steels with use of laser beam shaping systems

Abstract

Features of laser-assisted warm forming of dual phase steel DP1000 are determined. Simulation of forming processes with local heating is performed. In the simulation procedure, the forming parameters of three dimensional forming were adapted to keep them within tolerable limits even in critical areas as well as identifying the localization and type of critical stresses. The capabilities of Abaqus were extended by use of the Python language to independently evaluate selected element strains, the position of deformed elements within the forming limit diagram and user-defined failure criteria. The simulation led to an adapted forming process permitting a significantly increased bulge forming depth by local laser heating of the forming zones. The developed simulation model shows a satisfactory conformity with experiments, performed using a fibre-coupled laser with a wavelength of 1070 nm and a maximum output power of 1500 W, and a servo bending press TRUMPF TruBend 7018. The required distribution of the laser beam energy can be obtained by using diffractive optical elements. The use of the model for technological operations opens up possibilities not only for the solution of the presented specific objective of laser assisted warm forming, but also for others applications.