Abstract
Automatic process modeling has become an effective tool in reducing the lead-time and the cost for designing forming processes. The numerical modeling process is performed on a fully coupled damage constitutive equations and the advanced 3D adaptive remeshing procedure. Based on continuum damage mechanics, an isotropic damage model coupled with the Johnson–Cook flow law is proposed to satisfy the thermodynamic and damage requirements in metals. The Lemaitre damage potential was chosen to control the damage evolution process and the effective configuration. These fully coupled constitutive equations have been implemented into a Dynamic Explicit finite element code Abaqus using user subroutine. On the other hand, an adaptive remeshing scheme in three dimensions is established to constantly update the deformed mesh to enable tracking of the large plastic deformations. The quantitative effects of coupled ductile damage and adaptive remeshing on the sheet metal forming are studied, and qualitative comparison with some available experimental data are given. As illustrated in the presented examples this overall strategy ensures a robust and efficient remeshing scheme for finite element simulation of sheet metal‐forming processes.
Highlights
The commercial finite element software has integrated various material models to describe the thermal-visco-plastic behaviors of sheet metal in different forming processes
When materials are formed by these processes, they experience large plastic deformations leading to the onset of internal or surface micro-defects as voids and micro cracks
In this work the damage potential, introduced by Lemaitre [13], is used and coupled into an elasto-visco-plastic material model through defining the effective stress and plastic strain like a Johnson–Cook formulation [27]. 3D adaptive remeshing scheme using linear tetrahedral finite element is developed in order to simulate the large plastic deformations and crack propagation after damage occurring [28,29]
Summary
The commercial finite element software has integrated various material models to describe the thermal-visco-plastic behaviors of sheet metal in different forming processes (deep-drawing, hydroforming, incremental forming, blanking). The first uncoupled approach aims to calculate the damage (initiation and growth) distribution without taking into account its effect on the other mechanical fields (elastic, thermal, plastic, and hardening) This approach is used to predict zones where local failure has taken place inside the deformed work piece. 3D adaptive remeshing scheme using linear tetrahedral finite element is developed in order to simulate the large plastic deformations and crack propagation after damage occurring [28,29] This scheme is established to simulate to predict when and where ductile damage zones may take place inside the deformed part during tensile, compressive, and shearing tests. Four various sheet metal forming processes are proposed to prove that the numerical methodology is an advanced and a reliable tool to simulate various metal forming processes in order to avoid damage in incremental forming, deep drawing, and multi-point drawing or to enhance damage in order to simulate some sheet metal cutting operations
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