Journal articles: 'Forming simulations'

1

Myllykoski, P. "Using forming simulations to improve mechanical simulation accuracy." Journal of Materials Processing Technology 177, no. 1-3 (July 2006): 422–25. http://dx.doi.org/10.1016/j.jmatprotec.2006.04.096.

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Sherek, Paul A., Louis G. Hector, John R. Bradley, Paul E. Krajewski, and Eric M. Taleff. "Simulation and Experiments for Hot Forming of Rectangular Pans in Fine-Grained Aluminum Alloy AA5083." Key Engineering Materials 433 (March 2010): 185–95. http://dx.doi.org/10.4028/www.scientific.net/kem.433.185.

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Accurate numerical simulation capability is critical to the development and implementation of hot forming technologies. Numerical simulations were developed for gas-pressure forming of commercial, fine-grained aluminum-magnesium (AA5083) material into deep pan shapes at 450°C. These simulations utilize a material constitutive model recently developed for fine-grained AA5083 materials as a user-defined routine in commercial Finite Element Method (FEM) software. Results from simulations are compared against data from gas-pressure forming experiments, which used the same forming conditions and die geometries. Specifically, local sheet thinning and radius of curvature in edges and corners are compared between simulation and experiment. Numerical simulations are in good agreement with experiments for local sheet thinning of up to 50%. For locations where sheet thinning exceeds 50%, simulations predict less thinning and larger formed radii than observed in experiments. It is likely that cavitation, which is not accounted for in simulations, plays a significant role in causing a decrease in simulation prediction accuracy for thinning values greater than 50%. This study demonstrates a simulation capability that is potentially of significant practical use for predicting the hot gas-pressure forming of fine-grained AA5083 material.

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Abspoel, M., M. E. Scholting, and M. Lansbergen. "Thermomechanical forming and crash simulations." IOP Conference Series: Materials Science and Engineering 651 (November 25, 2019): 012044. http://dx.doi.org/10.1088/1757-899x/651/1/012044.

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Zhou, Tian Feng, Ji Wang Yan, and Tsunemoto Kuriyagawa. "Comparing Microgroove Array Forming with Micropyramid Array Forming in the Glass Molding Press." Key Engineering Materials 447-448 (September 2010): 361–65. http://dx.doi.org/10.4028/www.scientific.net/kem.447-448.361.

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This paper presents a glass molding press (GMP) method to fabricate microgroove array and micropyramid array on the glass plate by replicating the shape of the mold to the glass surface. The differences between microgroove forming and micropyramid forming were investigated by experiments and finite element method (FEM) simulations. Microgroove arrays and micropyramid arrays were generated on the flat glass plate in the GMP process by using an electroless-plated Nickel Phosphorus (Ni-P) mold, on which the microstructures are fabricated by micro cutting. Furthermore, FEM simulations were used to trace the stress distribution and the strain distribution during the glass deformation, which illustrates the glass material flow in the microgrooves and the micropyramids on the mold during pressing. By comparing the processes between microgroove forming and micropyramid forming, the differences between them observed in the experiments were explained by the simulation results. Finally, some techniques to improve the forming accuracy were proposed.

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Dubovská, Rozmarína, and Jozef Majerik. "Modeling and Virtual Simulation of Hard Surface Milling and Forming Process Using Advanced CAE Systems." Advanced Materials Research 941-944 (June 2014): 2321–31. http://dx.doi.org/10.4028/www.scientific.net/amr.941-944.2321.

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This paper presents the influence of modeling and simulation techniques for hard milling and forming. The aim of these simulations is the ability to optimize the manufacturing technologies even before the real production of its own tools, because their manufacturing process is very difficult in terms of production time, materials and other costs. The simulated results visualize roughing and finishing process of milling and generate tool-paths in CATIA V5. Simulation results of forming realized in PAM-Stamp 2G using a 3D model of the punch and the blank confirm the suitability of the proposed design of the forming tool. Finally, hard milling and forming simulations in CAE systems CATIA V5 and PAM-Stamp 2G were performed in order to determine and evaluation of suitability of the proposed shapes of the forming tool.

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Taylor, L., J. Cao, A. P. Karafillis, and M. C. Boyce. "Numerical simulations of sheet-metal forming." Journal of Materials Processing Technology 50, no. 1-4 (March 1995): 168–79. http://dx.doi.org/10.1016/0924-0136(94)01378-e.

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Governato, F., B. Willman, L. Mayer, A. Brooks, G. Stinson, O. Valenzuela, J. Wadsley, and T. Quinn. "Forming disc galaxies in CDM simulations." Monthly Notices of the Royal Astronomical Society 374, no. 4 (February 1, 2007): 1479–94. http://dx.doi.org/10.1111/j.1365-2966.2006.11266.x.

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Paunoiu, V., P. Cekan, E. Gavan, and D. Nicoara. "Numerical Simulations in Reconfigurable Multipoint Forming." International Journal of Material Forming 1, S1 (March 30, 2008): 181–84. http://dx.doi.org/10.1007/s12289-008-0021-4.

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Wróbel, Ireneusz, and Damian Firganek. "Simulations of hot forming processes of variable thicknesses workpieces." Mechanik 90, no. 11 (November 13, 2017): 991–93. http://dx.doi.org/10.17814/mechanik.2017.11.159.

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Methodology of production process analysis – by means of hot forming – using workpieces of variable thickness, was presented. Finite element simulations were performed using specialized software for the typical car body element – the longitudinal longeron. The simulation results were presented and discussed as well as conclusions and recommendations were formulated.

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Giraud-Moreau, Laurence, Jie Zhang, Abel Cherouat, and Houman Borouchaki. "Process Enhancement for Single Point Incremental Forming through a Remeshing Strategy." Advanced Materials Research 682 (April 2013): 135–41. http://dx.doi.org/10.4028/www.scientific.net/amr.682.135.

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Simulations of Single Point Incremental Forming generally require a very high computation time because the tool path is long and small elements are required everywhere on the sheet. In this paper, a remeshing method based on refinement and coarsening strategies is used with abaqus/explicit to reduce the computational time. The simulation of a semi-spherical cup with a fine mesh is considered as a reference simulation. The remeshing method allows reducing the number of elements and therefore the CPU time during the simulations. A good prediction is observed with the remeshing method.

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Huang, Hui, and Mikeal Nygårds. "Numerical Investigation of Paperboard Forming." Nordic Pulp & Paper Research Journal 27, no. 2 (May 1, 2012): 211–25. http://dx.doi.org/10.3183/npprj-2012-27-02-p211-225.

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Abstract A three dimensional numerical investigation of a commercial four-ply paperboard formed into a pear-shaped mould was presented. The numerical investigation included the effect of pressure, boundary conditions, material properties and different deformation and damage mechanisms such as delamination and plasticity. Simulations were done in both the MD and CD using different pressures. A paperboard model with a combination of anisotropic continuum model and a softening interface model had good deformation behavior during the forming simulations. Forming experiment that mimicked the simulations was performed. Numerical and experiment results were compared with good agreement.

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Zeng, Danielle, Laurent Chappuis, Z. Cedric Xia, and Xinhai Zhu. "A Path Independent Forming Limit Criterion for Sheet Metal Forming Simulations." SAE International Journal of Materials and Manufacturing 1, no. 1 (April 14, 2008): 809–17. http://dx.doi.org/10.4271/2008-01-1445.

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Chen, Li Jun, Geng Pei, Qing Bo Fang, and Jun Jie Pan. "A General Method of Numerical Simulation for Incremental Forming." Advanced Materials Research 403-408 (November 2011): 4084–88. http://dx.doi.org/10.4028/www.scientific.net/amr.403-408.4084.

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This paper presents a general simulation method for sheet metal incremental forming(ISF). Firstly, a three-dimensional finite element model based on Dynaform was developed to simulate the process. The tool path during the process simulation was directly defined by numerical control (NC) code and so identical with that in operation. Then, the results of numerical simulations with different process parameters, such as tool diameter, depth increment and wall angle, were discussed in details. The simulations reveal that with the decreasing depth step, increasing tool diameter and wall inclination angle, the axial stress reduces and leads to thinning reduction and more uniform thickness distribution. In addition, as the definition of the tool path was in accord with the genuine motion trajectory of the tool, the results deduced from this model may be more precise compared with those from other previously simplified models.

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Zhao, De Ying, Lian Dong Zhang, and Li Na Sun. "Forming Mechanism of Folding Defect within Closed Die Forming Car Steering Knuckle." Materials Science Forum 704-705 (December 2011): 240–44. http://dx.doi.org/10.4028/www.scientific.net/msf.704-705.240.

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Steering knuckle is the key part of vehicle steering system. The forming technology combined closed die pre-forging with open finish-forging has some advantages such as higher material utilization ratio and lower forming forces and so on. While simulating the closed die extrusion forming process of car steering knuckle, folding defect emerges on the contact area of Branch I and lower punch in the lateral extrusion process. The forming mechanism of the folding defect is studied by numerical simulations and experiments, which mainly consider the influence of lower punch shape and size, extrusion speed and friction conditions to folding length. The results show that the main factors that affect folding defects are the lower punch shape and size. Keywords: steering knuckle, folding defect, closed die forming, numerical simulation, experiment study

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Vijayan, Aditi, Biman B. Nath, Prateek Sharma, and Yuri Shchekinov. "Radio haloes of star-forming galaxies." Monthly Notices of the Royal Astronomical Society 492, no. 2 (December 23, 2019): 2924–35. http://dx.doi.org/10.1093/mnras/stz3568.

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ABSTRACT We study the synchrotron radio emission from extra-planar regions of star-forming galaxies. We use ideal magnetohydrodynamic simulations of a rotating Milky Way-type disc galaxy with distributed star formation sites for three star formation rates (0.3, 3, 30 M⊙ yr−1). From our simulations, we see emergence of galactic-scale magnetized outflows, carrying gas from the disc. We compare the morphology of the outflowing gas with hydrodynamic simulations. We look at the spatial distribution of magnetic field in the outflows. Assuming that a certain fraction of gas energy density is converted into cosmic ray energy density, and using information about the magnetic field, we obtain synchrotron emissivity throughout the simulation domain. We generate the surface brightness maps at 1.4 GHz. The outflows are more extended in the vertical direction than radial and hence have an oblate shape. We further find that the matter right behind the outer shock shines brighter in these maps than that above or below. To understand whether this feature can be observed, we produce vertical intensity profiles. We convolve the vertical intensity profile with the typical beam sizes of radio telescopes, for a galaxy located at 10 Mpc to estimate the radio scale height and compare with observations. The radio scale height is ∼300–1200 pc, depending on the resolution of the telescope. We relate the advection speed of the outer shock with the surface density of star formation as ${\rm v}_{\rm adv} \propto \Sigma _{\rm SFR}^{0.3}$, which is consistent with earlier observations and analytical estimates.

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Liu, Jun, Mei Ling Guo, Ming Jen Tan, and Beng Wah Chua. "FEM Study of Superplastic-Like Forming of Ti-6Al-4V Alloy." Materials Science Forum 783-786 (May 2014): 607–12. http://dx.doi.org/10.4028/www.scientific.net/msf.783-786.607.

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A superplastic-like forming (SPLF) process involving the use of hot drawing along with blow forming is studied here. The hot drawing stage helps in enhancing the formability and in fast forming the metal sheet into a hollow shape with desired amount of material draw-in. During the blow forming stage, gas pressure was applied onto the pre-formed part to complete the forming process at a targeted strain rate. Ti-6Al-4V sheets have been successfully formed by this process at 800 °C in 16 min. In this paper, finite element modeling (FEM) was used to demonstrate the effects of each stage (hot drawing and blow forming) during SPLF. A plasticity model based on tensile test data was adopted as a material model for simulation. The pressure cycle which was predicted from the simulation has been used in the process to maintain the sheet forming at an average strain rate (e.g. 10-3, 5×10-4 and 10-4 s-1. Experimental measurements, i.e. material draw-in and thickness distribution, were used to compare and validate the results from simulations. The validated simulations have shown the capability of the model to be used for the forming process. The influences of varying process parameters, such as drawing stroke, blank-holder force, friction coefficient and pressure cycle, were investigated by the simulations. It was found that the punch geometry and drawing stroke played significant roles on the thickness uniformity of the final part, from which an optimized hot-drawing system that could result in minimum thinning has been designed by FEM.

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Pilthammar, J., M. Sigvant, M. S. Islam, M. Schill, S. Sjöblom, V. Sjöblom, and M. Lind. "An overview of Methods for Simulating Sheet Metal Forming with Elastic Dies." IOP Conference Series: Materials Science and Engineering 1284, no. 1 (June 1, 2023): 012054. http://dx.doi.org/10.1088/1757-899x/1284/1/012054.

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Abstract Sheet metal forming (SMF) simulations are traditionally carried out with rigid active forming surfaces. This means that the elasticity and dynamics of presses and die structures are ignored. The only geometries of the tools included in the simulations are the active forming surfaces. One reason for this simplification is the large amount of computational power that is required to solve finite element (FE) models that incorporates elastic stamping dies. Another reason is the lack of die CAD models before the later stages of stamping projects. Research during the last couple of decades indicated potential large benefits when including elastic dies in SMF simulations. For example, for simulating die try-out or for Digital Twins of presses and dies. Even though the need and potential benefits of elastic dies in simulations are well known it is not yet implemented on a wide scale. The main obstacles have been lacking data on presses and dies, long simulation times, and no standardized implementation in SMF software. This paper presents an overview of existing methods for SMF simulations with elastic dies and discuss their respective benefits and drawbacks. The survey of methods shows that simulation models with elastic tools will be needed for detailed analyses of forming operations and also for purposes like digital twins. On the other hand, simplified and robust models can be developed for non-FEA users to carry out simple one-step compensation of tool surfaces for virtual spotting purposes. The most promising and versatile method from the literature is selected, modified, and demonstrated for industrial sized dies.

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Jung, Dong Won. "Investigation on Variation of Bow Defect in Roll Forming Process." Key Engineering Materials 729 (February 2017): 80–85. http://dx.doi.org/10.4028/www.scientific.net/kem.729.80.

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Roll forming is a kind of plastic forming process in which a steel strip is bent by several sets of rolls gradually into the desired shape. The products are cold roll forming steels with various sections. Roll forming is one of the most widely used processes in the world for forming metal. Roll forming is a complex deformation process, which involves large displacement, finite strain and the problems of contact and friction between strip and rolls. This process exhibits obvious geometry, physical and boundary nonliterary. The complex processes contain many aspects such as geometry, kinematics and dynamics, etc. The forming process involves not only transverse bending, but also other additional deformations. In this paper, a group of simulations have been established with ABAQUS software to studying about the spring back and bow defect in the roll forming process. At last, experiments have been accomplished to verify the simulation results. The simulations based on the ABAQUS software calculate the spring back angles and bow displacements. The bow displacement of the roll forming process is considered relate to many factors include inner distance between stands, gaps of the rolls, channel width, the material of the sheet, sheet thickness and so on.To verify the bow displacement in roll forming process, 9 groups of simulations were set up use Taguchi method to figure out the influence on bow displacement of every factor. The longitudinal strain also has been learned in the present study.

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Gallée, Sebastien, Antoine Martin, Vincent Robin, and Daniel Nelias. "Influence of Forming Residual Stresses on the Welding Distortions of Two Thick Plates." Advanced Materials Research 83-86 (December 2009): 125–32. http://dx.doi.org/10.4028/www.scientific.net/amr.83-86.125.

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The manufacturing of the ITER (International Thermonuclear Experimental Reactor) vacuum vessel involves the welding of thick deformed plates. The aim of this study is to investigate the influence of forming residual stresses on the welding distortions of two thick plates. The plates are deformed using a three point rolling process. A first numerical simulation is performed to investigate the residual stresses induced by this process. The forming residual stresses are taken into account as initial conditions to perform the electron beam welding simulation of a deformed plate. This simulation first requires calibrating the heat source. Two welding simulations are then performed: the first one with residual stresses and the second one without. The comparison of the simulation results points out a low effect of the residual stresses on the electron beam welding distortions. As a result, in the next electron beam welding simulations of the vacuum vessel, no forming residual stresses will be taken into account.

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Jeanson, Anne Claire, Gilles Avrillaud, Gilles Mazars, Jean Paul Cuq-Lelandais, Francois Bay, Elisabeth Massoni, Nicolas Jacques, and Michel Arrigoni. "Determination of High Strain-Rate Behavior of Metals: Applications to Magnetic Pulse Forming and Electrohydraulic Forming." Key Engineering Materials 611-612 (May 2014): 643–49. http://dx.doi.org/10.4028/www.scientific.net/kem.611-612.643.

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The design of processes like magnetic pulse forming and electrohydraulic forming involves multiphysical couplings that require numerical simulation, and knowledge on dynamic behaviour of metals. The forming process is completed in about 100 μs, so that the workpiece material deforms at strain-rates between 100 and 10 000 s-1. In this range, the mechanical behaviour can be significantly different than that in quasi-static conditions. It is often noticed that the strength and the formability are higher. The main goal of this study is to use an electromagnetically driven test on tubes or sheets to identify the constitutive behaviour of the workpiece material. In the case of tube, an industrial helix coil is used as inductor. Simulations with the code LS-Dyna® permit to find a configuration where the tube deforms homogeneously enough to allow axisymmetric modelling of the setup. The coil current is measured and used as an input for the simulations. The radial expansion velocity is measured with a Photon Doppler Velocimeter. The parameter identification is lead with the optimization software LS-Opt®. LS-Dyna axisymmetric simulations are launched which different set of parameters for the constitutive behaviour, until the computed expansion velocity fits the experimental velocity. The optimization algorithm couples a gradient method and a global method to avoid local minima. Numerical studies show that for the Johnson-Cook constitutive model, two or three experiments at different energies are required to identify the expected parameters. The method is applied to Al1050 tubes, as received and annealed. The parameters for the Johnson-Cook and Zerilli-Armstrong models are identified. The dynamic constitutive behaviour is compared to that measured on quasi-static tensile tests, and exhibits a strong sensitivity to strain-rate. The final strains are also significantly higher at high velocity, which is one of the major advantages of this kind of processes.

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Canales, Diego, Adrien Leygue, Francisco Chinesta, Elias Cueto, Eric Feulvarch, Jean Michel Bergheau, Yannick Vincent, and Frederic Boitout. "Efficient Updated-Lagrangian Simulations in Forming Processes." Key Engineering Materials 651-653 (July 2015): 1294–300. http://dx.doi.org/10.4028/www.scientific.net/kem.651-653.1294.

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A new efficient updated-Lagrangian strategy for numerical simulations of material forming processes is presented in this work. The basic ingredients are the in-plane-out-of-plane PGD-based decomposition and the use of a robust numerical integration technique (the Stabilized Conforming Nodal Integration). This strategy is of general purpose, although it is especially well suited for plateshape geometries. This paper is devoted to show the feasibility of the technique through some simple numerical examples.

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Lenz, Dominic A., Bianca M. Mladek, Christos N. Likos, Gerhard Kahl, and Ronald Blaak. "Monomer-Resolved Simulations of Cluster-Forming Dendrimers." Journal of Physical Chemistry B 115, no. 22 (June 9, 2011): 7218–26. http://dx.doi.org/10.1021/jp109132m.

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Schmid, S. R., J. Liu, M. A. Sellés, and T. Pasang. "Advanced interface models for metal forming simulations." Computational Materials Science 79 (November 2013): 763–71. http://dx.doi.org/10.1016/j.commatsci.2013.07.025.

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Yoon, Sangpil, Cheng-Tang Wu, Hui-Ping Wang, and Jiun-Shyan Chen. "Efficient Meshfree Formulation for Metal Forming Simulations." Journal of Engineering Materials and Technology 123, no. 4 (July 24, 2000): 462–67. http://dx.doi.org/10.1115/1.1396349.

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A stabilized conforming (SC) nodal integration method is developed for elastoplastic contact analysis of metal forming processes. In this approach, strain smoothing stabilization is introduced to eliminate spatial instability in collocation meshfree methods. The gradient matrix associated with strain smoothing satisfies the integration constraint (IC) of linear exactness in the Galerkin approximation. Strain smoothing formulation and numerical procedures for history-dependent problems are introduced. Applications to metal forming analysis are presented, with the results demonstrating a significant improvement in computational efficiency without loss of accuracy.

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Potluri, Prasad, Raj Ramgulam, Marco Chilo, and Haseeb Arshad. "Tow-Scale Mechanics for Composite Forming Simulations." Key Engineering Materials 504-506 (February 2012): 255–60. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.255.

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Abstract. Composites are processed by a variety of forming techniques at both preforming and consolidation stages; ranging from hand draping, diaphragm forming, vacuum infusion to Resin Transfer Molding. During these processes, individual fabric or prepreg layers are subjected to inplane tension and shear, inter-ply shear, transverse compression and out-of-plane bending forces. These forming forces are translated into individual tow-level forces leading to tow deformations. Each tow is subjected to tension, transverse compaction (in the plane of the fabric due to shear and normal to the fabric plane due to consolidation force), bending and torsion. The resulting tow geometry and local fibre volume fractions (within a tow) would have a significant impact on resin flow as well as mechanical properties of the composite. In this paper, we present computational as well as experimental approaches to predicting tow deformations, when subjected to various loading conditions. The test rigs, shown in figure 1, can measure stress-strain behaviour of a tow in bending, torsion and transverse compression respectively. Figure shows buckling of carbon tow – bending stiffness can be computed from the post-buckling behavior. Torsional moments at monotonically increased twist angle were measured using a very sensitive torque sensor. An anvil, nearly same size as a tow, is used to compress a tow (under controlled axial tension) and the cross-sectional shape is computed from the flattened image (recorded using a high resolution camera). A mechanics-based model has been developed to predict tow-scale deformations under transverse compression, tension, bending and torsion modes of deformation. Individual fibres in a tow are modeled as ‘3D elastica’ and a simple inter-fibre friction model has been incorporated. Initially developed for twisted fibre bundles, the elastic-based model works reasonably well for untwisted fibre tows (by assuming an extremely small twist level for convergence). Full paper will present comparison between experimental and theoretical results.

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Aimene, Y., B. Hagege, F. Sidoroff, E. Vidal-Sallé, P. Boisse, and S. Dridi. "Hyperelastic Approach for Composite Reinforcement Forming Simulations." International Journal of Material Forming 1, S1 (April 2008): 811–14. http://dx.doi.org/10.1007/s12289-008-0259-x.

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Atzema, Eisso, Michael Abspoel, Pascal Kömmelt, and Marc Lambriks. "Towards robust simulations in sheet metal forming." International Journal of Material Forming 2, S1 (August 2009): 351–54. http://dx.doi.org/10.1007/s12289-009-0534-5.

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Canup, Robin M. "Simulations of a late lunar-forming impact." Icarus 168, no. 2 (April 2004): 433–56. http://dx.doi.org/10.1016/j.icarus.2003.09.028.

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LI, JINGMEI, and SHELDON I. GREEN. "Fiber interaction with a forming fabric." August 2012 11, no. 8 (September 1, 2012): 39–46. http://dx.doi.org/10.32964/tj11.8.39.

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During sheet forming, the structure of the forming fabric leaves wire marks on the pulp mat. Paper nonuniformity caused by the wire mark can lead to ink nonuniformity in printing. We investigated wire mark numerically through simulations of the interaction of individual fibers with a forming fabric. In the simulations, the flow field through the forming fabric was taken to be that of single-phase water flow without disturbance of fibers. A particle level simulation method was applied to simulate the motion of fibers in the flow through a single layer sine-wave fabric. A hundred fibers of random initial distribution were placed into the flow above the fabric. Those fibers were advected onto the fabric, forming a fiber mat. The surface roughness of the resulting fiber mat was then calculated. The results show that during the initial formation, topographic wire mark is caused partially by fiber bending and partially by the geometry of the fabric. For the specific fibers and sinusoidal forming fabric considered, more than 50% of topographic wire mark is the result of geometry, with the remainder attributed to fiber bending. Fabrics with different geometries (e.g., different filament pitches or a nonsinusoidal geometry) will have different relative influences from geometry and fiber bending.

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Sigvant, M., J. Pilthammar, J. Hol, J. H. Wiebenga, T. Chezan, B. Carleer, and A. H. van den Boogaard. "Friction in Sheet Metal Forming: Forming Simulations of Dies in Try-Out." Journal of Physics: Conference Series 1063 (July 2018): 012134. http://dx.doi.org/10.1088/1742-6596/1063/1/012134.

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Ryou, Hansun, Kwansoo Chung, Jeong-Whan Yoon, Chung-Souk Han, Jae Ryoun Youn, and Tae Jin Kang. "Incorporation of Sheet-Forming Effects in Crash Simulations Using Ideal Forming Theory and Hybrid Membrane and Shell Method." Journal of Manufacturing Science and Engineering 127, no. 1 (February 1, 2005): 182–92. http://dx.doi.org/10.1115/1.1830050.

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In order to achieve reliable but cost-effective crash simulations of stamped parts, sheet-forming process effects were incorporated in simulations using the ideal forming theory mixed with the three-dimensional hybrid membrane and shell method, while the subsequent crash simulations were carried out using a dynamic explicit finite element code. Example solutions performed for forming and crash simulations of I- and S-shaped rails verified that the proposed approach is cost effective without sacrificing accuracy. The method required a significantly small amount of additional computation time, less than 3% for the specific examples, to incorporate sheet-forming effects into crash simulations. As for the constitutive equation, the combined isotropic-kinematic hardening law and the nonquadratic anisotropic yield stress potential as well as its conjugate strain-rate potential were used to describe the anisotropy of AA6111-T4 aluminum alloy sheets.

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Liu, Ming Jun, Zhen Yu Zhao, and Bai Liu. "Process Optimization for the Side-Plate of the Core Part in Parallel Flow Evaporator." Applied Mechanics and Materials 55-57 (May 2011): 961–65. http://dx.doi.org/10.4028/www.scientific.net/amm.55-57.961.

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The forming scheme of a side-plate of the core part in parallel flow evaporator was studied. Two forming schemes were compared and the explicit dynamic software DYNAFORM was applied to make simulations about the forming processes. According to comparisons between two forming schemes, the optimized scheme and process parameters were determined. Multi-station dies were designed based on the optimized process. Successful experiments with the dies showed that numerical simulation provided an efficient way for the optimization of the forming scheme in the side-plate production.

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Wang, Dao Kuan, Jun Song Jin, and Xin Yun Wang. "Investigation of a Two-Step Rotary Rim-Thickening Process of Disc-Like Blanks." Materials Science Forum 920 (April 2018): 89–94. http://dx.doi.org/10.4028/www.scientific.net/msf.920.89.

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A two-step rotary rim-thickening process of disc-like blanks was investigated by FE simulation and spinning experiments. The preforming shape of cross section for first step was designed as trapezium before forming rectangular-shape rim in the second step. The main factors influencing the blank forming in the first step were groove bottom height h1 and the inclination angle α of the roller. With the increase of h1 and α of the roller in FE simulation, the workpiece will be more prone to lose stability and cause defects. The forming limit diagram was obtained in first step, including stable forming zone, unstable forming zone and failed forming zone. Considering the stability and efficiency of thickening, four groups of h1 and α were selected for the second step simulation. Maximum rim thickness (h2) after second-step forming was 9 mm, obtained by trial and error in FE simulations. The spinning experiments were carried out to verify the validity of numerical simulation.

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Tang, Zibo, Wei Xiong, Ying Zheng, and Jin Zhang. "The Effects of Forming Angle on the Geometry Accuracy and Mechanical Properties of Al-Li Alloy Truncated Pyramids by Single Point Incremental Forming." Applied Sciences 13, no. 10 (May 17, 2023): 6144. http://dx.doi.org/10.3390/app13106144.

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In this study, single point incremental forming (SPIF) of Al-Li alloy sheets under different forming angles are studied via both experimental methods and numerical simulations. The effect of different forming angle on the geometric accuracy of SPIFed Al-Li component is studied. The simulation results show that the higher the forming angle, the lower the stress at the corner, leading to better geometrical accuracy, which is also experimentally validated. It is also found that high forming angle leads to better mechanical properties of the SPIFed Al-Li alloy component.

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Phan, Thi-Ha-Linh, The-Thanh Luyen, and Duc-Toan Nguyen. "A Study Utilizing Numerical Simulation and Experimental Analysis to Predict and Optimize Flange-Forming Force in Open-Die Forging of C45 Billet Tubes." Applied Sciences 13, no. 16 (August 8, 2023): 9063. http://dx.doi.org/10.3390/app13169063.

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Open-die forging holds a pivotal role in shaping machine parts within industrial applications. This study focuses on the assessment of stress–strain curves for C45 material at different elevated temperatures and strain rates through numerical simulations employing the finite element method (FEM). Specifically, the research investigates how the flow curve of materials at elevated temperatures and individual strain rates impacts the forming force during the flange forming of C45 billet tubes. By comparing the simulation results with experimental data on the flange-forming force, this study observes that optimal outcomes arise when considering both elevated temperature and strain rates in the flow curve of materials. The study then conducts simulations for C45 billet tubes with varying upsetting ratios (H0/D0), (S0/D0), and the punch’s pitch angle (α), aiming to address optimization challenges related to the flange-forming force. Consequently, a mathematical model is developed to represent the relationship between the flange-forming force and geometric parameters (H0/D0, S0/D0, and α). This model accurately predicts the forming force under various flange-forming conditions, demonstrating high precision with a maximum error of 4.26% compared with the experimental results. This study significantly contributes to the advancement of flange-forming technology in open-die forging through numerical simulation, enabling the optimization of the flange-forming force and the selection of appropriate equipment. These findings pave the way for more effective and efficient industrial processes, fostering innovation and progress in the field.

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Woźniak, D., M. Głowacki, M. Hojny, and T. Pieja. "Application of CAE Systems in Forming of Drawpieces with Use Rubber-Pad Forming Processes / Zastosowanie Systemów CAE W Projektowaniu Procesów Tłoczenia Z Użyciem Odkształcalnych Narzędzi." Archives of Metallurgy and Materials 57, no. 4 (December 1, 2012): 1179–87. http://dx.doi.org/10.2478/v10172-012-0132-2.

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This article shows example result of computer simulations supporting production process of bearing housing of aircraft engine. Verification of both deep drawing process project and tools design were carried out using finite element models implemented in eta/Dynaform 5.8.1 system and LS-DYNA solver. Wrinkling and fracture of the material were the main phenomena subjected to the investigation on the way of numerical analysis. A number of computer simulations were carried out in aim to analyze the deformation and strain distribution in the final product, as well as to eliminate the mentioned defects. In addition the comparison of results of both industrial tests and computer simulation was done.

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Gatouillat, S., A. Barregi, Emmanuelle Vidal-Sallé, and Philippe Boisse. "Simulation of Composite Forming at Meso Scale." Key Engineering Materials 554-557 (June 2013): 410–15. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.410.

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The forming simulation of woven reinforcements allows accessing to information such as fibre position after forming but also deformation state as well as predicting defects such as wrinkles, yarn sliding, and fibre/yarn fracture. The proposed model consists in a mesoscopic description of the reinforcement. It is simple enough to render the simulation of the forming preform possible but describes also properly the main phenomena occurring during the forming. A geometrical model where each yarn is modelled using shell elements in contact-friction with its neighbours is proposed. A hypoelastic behaviour specific of the yarn is used. Identification and validation of the model are done using standard characterisation tests for fabrics. Forming simulations illustrate the capabilities of the proposed approach. A main interest of such modelling is the possibility for the simulation to exhibit large sliding between warp and weft yarns when the tensile loads are too important.

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Hu, Han, Feng Yu, Song Zhang, Jing Yin, Haiyan Zhang, Jiaru Zhang, Xiaonan Zhang, Miaoyan Cao, and Shahzad Murtaza. "Ultrasonic-Assisted Granular Medium Forming of Aluminum Alloy 6063-T5: Simulations and Experiments." Metals 14, no. 8 (July 24, 2024): 847. http://dx.doi.org/10.3390/met14080847.

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To address the challenges posed by the complex shapes of hollow parts, this study examined the ultrasonic-assisted granular medium hydroforming (UGMF) process for tubular components. The dynamics of the deformation behavior and deformation control during 6063-T5 aluminum alloy tube free forming by UGMF were studied via simulations and experiments. Based on the ABAQUS software platform, a coupled method based on finite element (FE) simulation analysis and discrete element (DE) analysis for the UGMF free forming process was used. The results showed that ultrasonic vibration (UV) could reduce the forming force required for expansion and promote the flow of material at the end to the forming area as well as inhibit the decrease in the wall thickness. The accuracy of the FE-DE coupled simulation model and a parabolic geometric model was verified by testing. The results found that UV enhances material flow, decreases the forming force needed, and minimizes damage to the granular surface.

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van den Boogaard, A. H., H. H. Wisselink, and J. Huétink. "Do Advanced Material Models Contribute to Accuracy in Industrial Sheet Forming Simulations?" Advanced Materials Research 6-8 (May 2005): 71–80. http://dx.doi.org/10.4028/www.scientific.net/amr.6-8.71.

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The accuracy of material models can have a large impact on the overall accuracy of material forming simulations in general and sheet forming simulations in particular. For large strain plastic deformations, the material model usually consists of a yield function and a hardening relation, optionally including the influence of temperature and strain rate. In large-scale simulations it is favourable to keep the model as simple as possible. The ‘allowable’ error in a material model should be in balance with other errors, like the discretisation error and errors in contact and friction modelling. The required accuracy depends on the application and the goal of the analysis. In many occasions, strain rate and temperature dependency can be ignored, but for warm forming this is clearly not the case. Furthermore, numerical simulation of the onset of necking requires a much better material model than needed for the calculation of the global deformation field before necking.

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Čada, Radek, and Petr Tiller. "Evaluation of Draw Beads Influence on Intricate Shape Stamping Drawing Process." Technological Engineering 11, no. 1 (December 1, 2014): 5–10. http://dx.doi.org/10.2478/teen-2014-0001.

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Abstract Paper concerns evaluation of influence of shape, size and location of rectangular and semicircular draw beads on sheet-metal forming process. For analysis the simulations of forming process of selected two types of intricate shape stampings with similar ground plan and with approximately the same height from steel strip DC04 with the use of models of optimal blanks made by BSE (Blank Size Engineering) modul of simulation program Dynaform 5.7 were carried out. From simulations of forming process in simulation program Dynaform 5.7 followed that the most suitable is drawing without use of draw beads because cracks in stamping bottom corners do not arise. In the case of undesirable secondary waviness in the walls of intricate shape stamping the drawing with draw beads could be used but it would be necessary to increase the radius at the bottom of both stampings alternatively to choose another material with higher formability.

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Zettler, Joachim, and Sjoerd van der Veen. "Novel Aerospace Architectures Made Possible by Forming Simulation." Key Engineering Materials 554-557 (June 2013): 1872–78. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.1872.

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In the aerospace industry lightweight design in combination with fast and reliable manufacturing processes are key components to defend the leading position in the worldwide competition. In this frame it is an overall goal to reduce the number of process steps in order to produce parts for an aircraft to its minimum. Integral design is one way to cope with this goal but on the other hand raises a lot of problems that may occur in manufacturing or final assembly. To be able to predict potential bottlenecks or drawbacks in certain designs, finite element simulation can be helpful. Especially if it’s an early design phase and new material concepts are taking into account, the virtual manufacturing, done by finite element simulations is the only way to predict real life behavior. In this paper we will focus on the use and benefit of finite element simulations in the early design phase of very huge integral parts of a next generation aircraft. The parts do belong to the nose fuselage structure and will be manufactured from a 100-150mm thick AlMgSc plate. Two different manufacturing routes will be covered by simulation. 1. Hot forming the plates at around 300°C and machining 2. Explosive forming of the plates and machining For both routes, a complete simulation chain from forming over springback to final machining is developed and presented in detail. Special care is taken on a fully automated workflow from one step to the other to allow an easy adaptation to other part geometries in the future. To ensure a high quality of the simulation results all process steps of the hot forming route are simulated with ABAQUS implicit and approved constitutive laws. The explosive forming manufacturing route is simulated using an Eulerian-Lagrange approach taken into account the various possibilities of detonation loading. To validate the simulation results to real measurements, a scaled down version of one of the parts is manufactured in reality and each process step is compared with the simulation result.

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Albut, Aurelian, and Vlad Ciubotariu. "Optimization of the Blank Holder Force Using Genetic Algorithm Method in Case of a U - Shaped Part." Key Engineering Materials 549 (April 2013): 247–52. http://dx.doi.org/10.4028/www.scientific.net/kem.549.247.

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In case of sheet metal forming the main dimensional errors are caused by the springback phenomena. The present work deals with numerical simulation related to draw bending and springback of U - shaped parts. The current paper is trying to prove out the important role of the blank holder force variation during the forming process. The Dynaform 5.8 software was used to simulate the forming process, in which the blank holder force varies in four steps between 0 and 50 kN. The factorial simulations test plan was made to cover completely the variation domain and 256 simulations were necessarily to be performed. The part obtained after each simulation is analyzed and measured to quantify the errors caused by springback. Parameters as: angle between flange and sidewall, angle between sidewall and part bottom, chamfer radius between part bottom and sidewall or chamfer radius between sidewall and flange are recorded in a data base. The initial simulations plan together with the generated data base is used as an input for the genetic algorithm optimization method. With the optimized process parameters a new simulation is made and the final shape of the part is compared with the ideal geometry. The shape of the part obtained with the optimized parameters is proving the capability of the proposed method.

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Sheu, Jinn-Jong, Chien-Jen Ho, Cheng-Hsien Yu, and Kuo-Ting Wu. "Fastener products lightweight design and forming process simulation." MATEC Web of Conferences 185 (2018): 00030. http://dx.doi.org/10.1051/matecconf/201818500030.

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In this research, an integrated design system was established to design the product of nuts with flange and generate the lightweight geometry of product. The multi-stage forming process was evaluated using the CAE simulations. The topology optimization method was used to achieve the lightweight design, that included keeping necessary geometrical features and remove the excess volumes. The topological discrete model had been remodelled into a meaningful geometry which is able to satisfy the requirement of proof load of fastener specification. The final design of the lightweight geometry was adopted to test the capability of carrying proof load required using CAE simulations with the boundary conditions of the related ASTM standard. In the evaluation stage, the finite element method was used to do the topology optimization, the proof load evaluation, the forging process and the die stress analysis. The simulation results showed the lightweight design was able to reduce the weight of product and maintain enough mechanical strength. The proposed process and die designs were able to obtain the lightweight product without defects.

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Nakamura, Fumitaka, and Zhi-Yun Li. "Protostellar turbulence in cluster forming regions of molecular clouds." Proceedings of the International Astronomical Union 2, S237 (August 2006): 306–10. http://dx.doi.org/10.1017/s1743921307001640.

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AbstractWe perform 3D MHD simulations of cluster formation in turbulent magnetized dense molecular clumps, taking into account the effect of protostellar outflows. Our simulation shows that initial interstellar turbulence decays quickly as several authors already pointed out. When stars form, protostellar outflows generate and maintain supersonic turbulence that have a power-law energy spectrum of Ek ~ k−2, which is somewhat steeper than those of driven MHD turbulence simulations. Protostellar outflows suppress global star formation, although they can sometimes trigger local star formation by dynamical compression of pre-existing cores. Magnetic field retards star formation by slowing down overall contraction. Interplay of protostellar outflows and magnetic field generates large-amplitude Alfven and MHD waves that transform outflow motions into turbulent motions efficiently. Cluster forming clumps tend to be in dynamical equilibrium mainly due to dynamical support by protostellar outflow-driven turbulence (hereafter, protostellar turbulence).

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Haanappel, Sebastiaan P., Ulrich Sachs, Rene H. W. ten Thije, Bert Rietman, and Remko Akkerman. "Forming of Thermoplastic Composites." Key Engineering Materials 504-506 (February 2012): 237–42. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.237.

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Design and production guidelines for UD reinforced thermoplastic composites are highly desirable. Therefore, forming experiments and simulations with a realistic complex shaped product were conducted. Thermoforming experiments with quasi-isotropic UD carbon/PEEK and 8HS woven glass/PPS composites showed a clear difference in formability. Many wrinkles develop near doubly curved areas for the considered UD composites, whereas significant in-plane shear is observed for the woven composites. Forming prediction tools can be utilised to optimise the product design with respect to formability. A forming prediction methodology is shown, which encompasses finite element modelling in combination with material models that describe major deformation mechanisms. Characterisation methods were developed to describe inter-ply friction and in-plane shear. Forming simulations are able to indicate the critical areas for the UD composites, as is concluded from the comparison of wrinkling and in-plane shear distributions within the formed specimens. Forming experiments and predictions match qualitatively well and this tool can successfully be utilised in the product design phases.

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Kronsteiner, Johannes, Elias Theil, Alois Christian Ott, Aurel Ramon Arnoldt, and Nikolaus Peter Papenberg. "Modeling of Texture Development during Metal Forming Using Finite Element Visco-Plastic Self-Consistent Model." Crystals 14, no. 6 (June 5, 2024): 533. http://dx.doi.org/10.3390/cryst14060533.

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In directional forming processes, such as rolling and extrusion, the grains can develop preferred crystal orientations. These preferred orientations—the texture—are the main cause for material anisotropy. This anisotropy leads to phenomena such as earing, which occur during further forming processes, e.g., during the deep drawing of sheet metal. Considering anisotropic properties in numerical simulations allows us to investigate the effects of texture-dependent defects in forming processes and the development of possible solutions. Purely phenomenological models for modeling anisotropy work by fitting material parameters or applying measured anisotropy properties to all elements of the part, which remain constant over the duration of the simulation. In contrast, crystal plasticity methods, such as the visco-plastic self-consistent (VPSC) model, provide a deeper insight into the development of the material microstructure. By experimentally measuring the initial texture and using it as an initial condition for the simulations, it is possible to predict the evolution of the microstructure and the resulting effect on the mechanical properties during forming operations. The results of the simulations with the VPSC model show a good agreement with corresponding compression tests and the earing phenomenon, which is typical for cup deep drawing.

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Sakash, Aaron, Sumit Moondra, and Brad L. Kinsey. "Effect of Yield Criterion on Numerical Simulation Results Using a Stress-Based Failure Criterion." Journal of Engineering Materials and Technology 128, no. 3 (March 19, 2006): 436–44. http://dx.doi.org/10.1115/1.2204951.

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Determining tearing concerns in numerical simulations of sheet metal components is difficult since the traditional failure criterion, which is strain-based, exhibits a strain path dependence. A stress-based, as opposed to a strain-based, failure criterion has been proposed and demonstrated analytically, experimentally in tube forming, and through numerical simulations. The next step in this progression to the acceptance of a stress-based forming limit diagram is to demonstrate how this failure criterion can be used to predict failure of sheet metal parts in numerical simulations. In this paper, numerical simulation results for dome height specimens are presented and compared to experimental data. This procedure was repeated for various yield criteria to examine the effect of this parameter on the ability to predict failure in the numerical simulations. Reasonable agreement was obtained comparing the failure predicted from numerical simulations and those found experimentally, in particular for the yield criterion which has been shown to best characterize the material used in this study.

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Więckowski, Wojciech. "Numerical Simulation of Forming Process for Cover with Stiffening Components Made of Grade 2 Titanium Sheet Metal." Key Engineering Materials 687 (April 2016): 206–11. http://dx.doi.org/10.4028/www.scientific.net/kem.687.206.

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This study presents the findings of numerical simulations of forming process for an inspection hole cover with stiffening ribs made of thin grade 2 titanium sheet metal. The numerical simulation was carried out using the FEM method with PAMStamp 2G software. Numerical calculations were performed with consideration for the phenomenon of material strain hardening and anisotropy of plastic properties of the sheet metal formed. Properties of the grade 2 titanium alloy analysed in the simulations were adopted based on the results of the empirical studies. Adequate parameters of the forming process were selected in order to eliminate unfavourable phenomena of losing of material coherence and sheet metal wrinkling. The effect of conditions of friction between the sheet metal and tool and pressure force of the blank holder on the forming process was investigated. The analysis of the distribution of plastic strain and reduction in wall thickness of the drawn parts can be used for determination of the effect of changes in selected parameters and orientation of the specimen on the process of drawn part forming. The quality of drawn parts was assessed based on the shape inaccuracy determined during simulation of forming. The inaccuracy depended on the conditions of the process and strength properties of the titanium sheet metal.

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Narowski, Przemysław, and Krzysztof Wilczyński. "A Global Approach to Modeling Injection Molding." Polymers 16, no. 1 (January 3, 2024): 147. http://dx.doi.org/10.3390/polym16010147.

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A problem of modeling plastic injection forming (molding) is presented, including both the plasticizing system of the injection-forming machine and the mold. When modeling the plastic flow in the mold, the input quantities are essentially unknown, e.g., the plastic melt temperature. Thus, a comprehensive (global) model of the injection-forming process is needed for the flow in the plasticizing system and in the mold. The process output quantities from the plasticizing system will be the input quantities for the mold. When modeling the plastic flow in the injection-forming machine, a comprehensive approach should be applied to consider the solid material conveying, material plasticizing, and the material melt flow. The model of material plasticizing is a basis for building such global models. In this research, the effect of the flow (including plasticizing) in the injection-forming machine on the flow in the mold is studied by simulation (using Moldex3D 2023R3OR 64-bit software) and experimentation. These studies are carried out for the injection forming of selected material using a specialized spiral mold. Simulations performed with the use of Moldex3D software for the plasticizing system significantly improved the accuracy of the simulation of the flow in the mold. However, the best results were obtained using experimental data (plastic melt temperature) as input quantities for mold filling simulations. The novel concepts of injection-forming process modeling based on our previous experimentations are also discussed.

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Kim, Young Suk, Duy Tung Do, Dae Cheol Ahn, and Dong Woo Shin. "Finite Element Simulations for CFRP Press Forming Process." Key Engineering Materials 651-653 (July 2015): 415–22. http://dx.doi.org/10.4028/www.scientific.net/kem.651-653.415.

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The macro-scale and meso/macro-scale simulations for press forming of CFRP sheet using ABAQUS S/W were both implemented to study the influence fiber orientation on the formability of CFRP sheet. The Hashin damage criterion was used to predict the fiber failure in the forming process. The properties of plain woven fiber fabric were obtained from the tensile test and bias extension test. The forming experiments with rectangular punch were carried out to validate the numerical results.

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Journal articles on the topic 'Forming simulations'

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