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Introduction of elastic die deformations in sheet metal forming simulations
Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
2016 (English)In: International Journal of Solids and Structures, ISSN 0020-7683, E-ISSN 1879-2146Article in journal (Refereed) Epub ahead of print
Abstract [en]

Simulations of sheet metal forming (SMF) with finite element models (FE-models) for stamped parts in the car industry are useful for detecting and solving forming problems. However, there are several issues that are challenging to analyze. Virtual tryout and analyzes of stamping dies in running production are two important cases where many of these challenging issues are present. Elastic deformations of dies and press lines and a physically based friction model is often missing when these types of cases are analyzed. To address this, this research aims to develop a method wherein the results of two separate FE-models are combined to enable SMF simulations with the inclusion of elastic tool and press deformations. The two FE-models are one SMF model with two-dimensional (2D) rigid tool surfaces and one structural model of the die and press. The structural model can predict surface shapes and pressure distributions for a loaded stamping die. It can also visualize relatively large and unexpected deformations of the die structure. The recommended method of transferring the deformations from the structural model to the 2D surfaces is through an FE technique called submodeling. The subsequent SMF simulations show that the method for calculating and using the deformed surfaces together with the TriboForm friction model yields a result that matches measured draw-in and strains. It is verified that the ability to virtually deform a die and include the resulting geometry in forming simulations is of high importance. It can be used for the virtual tryout and optimization of new dies or analyses of existing dies in running production. It is suggested that future research focus on a more efficient and automated workflow. More experimental data and simulations are also needed to verify the assumptions made for the simulation models. This will enable the method to be adopted in a reliable way for standard SMF simulations. © 2017.

Place, publisher, year, edition, pages
Elsevier Ltd , 2016.
Keyword [en]
Elastic tooling, Friction, Sheet metal forming, Structural analysis, Surface compensation, Automotive industry, Computer supported cooperative work, Deformation, Dies, Metal forming, Presses (machine tools), Sheet metal, Stamping, Tribology, Automated workflow, Forming simulations, Friction modeling, Physically based, Research focus, Structural modeling, Two Dimensional (2 D), Finite element method
National Category
Materials Engineering
Identifiers
URN: urn:nbn:se:bth-14475DOI: 10.1016/j.ijsolstr.2017.05.009ScopusID: 2-s2.0-85019444887OAI: oai:DiVA.org:bth-14475DiVA: diva2:1108795
Available from: 2017-06-13 Created: 2017-06-13 Last updated: 2017-06-13

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Pilthammar, JohanSigvant, MatsKao-Walter, Sharon
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