Title

METAL FORMING SIMULATION USING A MESHLESS METHOD

METAL FORMING SIMULATION USING A MESHLESS METHOD

Authorship

ROQUE, CRISTINA MARIA OLIVEIRA LIMA; CHEN, JIUNSHYAN; PAN, CHUNHUI; BUTTON, SÉRGIO TONINI

ROQUE, CRISTINA MARIA OLIVEIRA LIMA

I am this author

CHEN, JIUNSHYAN

I am this author

PAN, CHUNHUI

I am this author

BUTTON, SÉRGIO TONINI

I am this author

DOI

10.5151/2594-5327-C00292-4576-4588

Downloads

Abstract

Practical tests to determine forming conditions for a new part can be very expensive and wasteful, and reduction in prototype manufacturing costs is clearly valuable. It is therefore important to provide guidance from a theoretical model which can be easily modified, provided that the model is representative and reliable. Despite its success in the analysis of geometric and material nonlinear behavior in structures and solids, the widely used Finite Element methods exhibit a number of shortcomings in handling problems involving large deformation, high gradients, or moving discontinuities. These difficulties are partially due to the regularity requirement of mesh. In the metal forming simulation, the Finite Element analysis procedures become tedious and ineffective in dealing with excessive plastic deformation and complex contact conditions. Mesh distortion is one of the major difficulties in the Finite Element analysis of metal forming. In this paper, a Meshless method based on a Reproducing Kernel Particle approximation is applied to the simulation of metal forming processes. With this approach, the workpiece is modeled by a set of particles without the use of a structured mesh. The development of the smooth Meshless shape functions are particularly effective in dealing with large material distortion and complex contact conditions involved in the metal forming simulation. Model refinement can be performed by a direct node insertion or deletion in the critical or non-critical areas in the workpiece without tedious remeshing. The developed Meshless method is applied to the ring compression and sheet metal problems to demonstrate the effectiveness of the proposed method.

Practical tests to determine forming conditions for a new part can be very expensive and wasteful, and reduction in prototype manufacturing costs is clearly valuable. It is therefore important to provide guidance from a theoretical model which can be easily modified, provided that the model is representative and reliable. Despite its success in the analysis of geometric and material nonlinear behavior in structures and solids, the widely used Finite Element methods exhibit a number of shortcomings in handling problems involving large deformation, high gradients, or moving discontinuities. These difficulties are partially due to the regularity requirement of mesh. In the metal forming simulation, the Finite Element analysis procedures become tedious and ineffective in dealing with excessive plastic deformation and complex contact conditions. Mesh distortion is one of the major difficulties in the Finite Element analysis of metal forming. In this paper, a Meshless method based on a Reproducing Kernel Particle approximation is applied to the simulation of metal forming processes. With this approach, the workpiece is modeled by a set of particles without the use of a structured mesh. The development of the smooth Meshless shape functions are particularly effective in dealing with large material distortion and complex contact conditions involved in the metal forming simulation. Model refinement can be performed by a direct node insertion or deletion in the critical or non-critical areas in the workpiece without tedious remeshing. The developed Meshless method is applied to the ring compression and sheet metal problems to demonstrate the effectiveness of the proposed method.

Keywords

metal forming simulation, meshless method, reproducing kernel particle method, large deformation, plastic distortion

metal forming simulation, meshless method, reproducing kernel particle method, large deformation, plastic distortion