An investigation on the accuracy of numerical simulations for single point incremental forming with continuum elements

R. Malhotra*, Yonggang Huang, L. Xue, Jian Cao, T. Belytschko

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contribution

11 Citations (Scopus)

Abstract

Finite element methods (FEM) have been widely used in simulating the single point incremental forming (SPIF) process to investigate the effects of process parameters, such as incremental depth, tool size and tool path on the thickness/strain distributions, deformed shapes, and the formability. However, due to the complexity of the process and the continuous change of the contact area in SPIF, numerical simulations tend to be time-consuming and hard to converge when an implicit integration method is used. To meet these challenges, most simulation work found in literature utilized the explicit integration method with shell elements to simulate the SPIF process. However, results have not been found satisfactory as evident by mismatches of the predicted shape, strain/thickness distribution and/or forming force between simulation and experimental results. In our past work, in order to obtain a more accurate result and consider the contact force in the thickness direction, solid continuum elements were introduced combined with the implicit method. Although the trends of the forming force in the Z direction were very similar between simulations and experimental results, there still existed a relatively large discrepancy in absolute values. In this paper, effects of yield criterion, element size and element type on the predicted forming force are investigated. Additionally, a new damage model has been incorporated into FEM simulation that, for the first time, predicts the force curve, the location of fracture and the maximum thinning with remarkable accuracy.

Original languageEnglish (US)
Title of host publicationNUMIFORM 2010 - Proceedings of the 10th International Conference on Numerical Methods in Industrial Forming Processes Dedicated to Professor O. C. Zienkiewicz (1921-2009), Volume 1 and 2
Pages221-227
Number of pages7
DOIs
StatePublished - Sep 3 2010
Event10th International Conference on Numerical Methods in Industrial Forming Processes Dedicated to Professor O. C. Zienkiewicz (1921-2009), NUMIFORM 2010 - Pohang, Korea, Republic of
Duration: Jun 13 2010Jun 17 2010

Publication series

NameAIP Conference Proceedings
Volume1252
ISSN (Print)0094-243X
ISSN (Electronic)1551-7616

Other

Other10th International Conference on Numerical Methods in Industrial Forming Processes Dedicated to Professor O. C. Zienkiewicz (1921-2009), NUMIFORM 2010
CountryKorea, Republic of
CityPohang
Period6/13/106/17/10

Fingerprint

continuums
simulation
finite element method
strain distribution
damage
trends
curves

Keywords

  • Fracture Envelope
  • Hardening Law
  • Incremental Forming
  • Numerical Simulations

ASJC Scopus subject areas

  • Physics and Astronomy(all)

Cite this

Malhotra, R., Huang, Y., Xue, L., Cao, J., & Belytschko, T. (2010). An investigation on the accuracy of numerical simulations for single point incremental forming with continuum elements. In NUMIFORM 2010 - Proceedings of the 10th International Conference on Numerical Methods in Industrial Forming Processes Dedicated to Professor O. C. Zienkiewicz (1921-2009), Volume 1 and 2 (pp. 221-227). (AIP Conference Proceedings; Vol. 1252). https://doi.org/10.1063/1.3457555
Malhotra, R. ; Huang, Yonggang ; Xue, L. ; Cao, Jian ; Belytschko, T. / An investigation on the accuracy of numerical simulations for single point incremental forming with continuum elements. NUMIFORM 2010 - Proceedings of the 10th International Conference on Numerical Methods in Industrial Forming Processes Dedicated to Professor O. C. Zienkiewicz (1921-2009), Volume 1 and 2. 2010. pp. 221-227 (AIP Conference Proceedings).
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abstract = "Finite element methods (FEM) have been widely used in simulating the single point incremental forming (SPIF) process to investigate the effects of process parameters, such as incremental depth, tool size and tool path on the thickness/strain distributions, deformed shapes, and the formability. However, due to the complexity of the process and the continuous change of the contact area in SPIF, numerical simulations tend to be time-consuming and hard to converge when an implicit integration method is used. To meet these challenges, most simulation work found in literature utilized the explicit integration method with shell elements to simulate the SPIF process. However, results have not been found satisfactory as evident by mismatches of the predicted shape, strain/thickness distribution and/or forming force between simulation and experimental results. In our past work, in order to obtain a more accurate result and consider the contact force in the thickness direction, solid continuum elements were introduced combined with the implicit method. Although the trends of the forming force in the Z direction were very similar between simulations and experimental results, there still existed a relatively large discrepancy in absolute values. In this paper, effects of yield criterion, element size and element type on the predicted forming force are investigated. Additionally, a new damage model has been incorporated into FEM simulation that, for the first time, predicts the force curve, the location of fracture and the maximum thinning with remarkable accuracy.",
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Malhotra, R, Huang, Y, Xue, L, Cao, J & Belytschko, T 2010, An investigation on the accuracy of numerical simulations for single point incremental forming with continuum elements. in NUMIFORM 2010 - Proceedings of the 10th International Conference on Numerical Methods in Industrial Forming Processes Dedicated to Professor O. C. Zienkiewicz (1921-2009), Volume 1 and 2. AIP Conference Proceedings, vol. 1252, pp. 221-227, 10th International Conference on Numerical Methods in Industrial Forming Processes Dedicated to Professor O. C. Zienkiewicz (1921-2009), NUMIFORM 2010, Pohang, Korea, Republic of, 6/13/10. https://doi.org/10.1063/1.3457555

An investigation on the accuracy of numerical simulations for single point incremental forming with continuum elements. / Malhotra, R.; Huang, Yonggang; Xue, L.; Cao, Jian; Belytschko, T.

NUMIFORM 2010 - Proceedings of the 10th International Conference on Numerical Methods in Industrial Forming Processes Dedicated to Professor O. C. Zienkiewicz (1921-2009), Volume 1 and 2. 2010. p. 221-227 (AIP Conference Proceedings; Vol. 1252).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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N2 - Finite element methods (FEM) have been widely used in simulating the single point incremental forming (SPIF) process to investigate the effects of process parameters, such as incremental depth, tool size and tool path on the thickness/strain distributions, deformed shapes, and the formability. However, due to the complexity of the process and the continuous change of the contact area in SPIF, numerical simulations tend to be time-consuming and hard to converge when an implicit integration method is used. To meet these challenges, most simulation work found in literature utilized the explicit integration method with shell elements to simulate the SPIF process. However, results have not been found satisfactory as evident by mismatches of the predicted shape, strain/thickness distribution and/or forming force between simulation and experimental results. In our past work, in order to obtain a more accurate result and consider the contact force in the thickness direction, solid continuum elements were introduced combined with the implicit method. Although the trends of the forming force in the Z direction were very similar between simulations and experimental results, there still existed a relatively large discrepancy in absolute values. In this paper, effects of yield criterion, element size and element type on the predicted forming force are investigated. Additionally, a new damage model has been incorporated into FEM simulation that, for the first time, predicts the force curve, the location of fracture and the maximum thinning with remarkable accuracy.

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Malhotra R, Huang Y, Xue L, Cao J, Belytschko T. An investigation on the accuracy of numerical simulations for single point incremental forming with continuum elements. In NUMIFORM 2010 - Proceedings of the 10th International Conference on Numerical Methods in Industrial Forming Processes Dedicated to Professor O. C. Zienkiewicz (1921-2009), Volume 1 and 2. 2010. p. 221-227. (AIP Conference Proceedings). https://doi.org/10.1063/1.3457555