Accounting for material scatter in sheet metal forming simulations

J.H. Wiebenga, E.H. Atzema, E.H. Atzema, R. Boterman, M. Abspoel, Antonius H. van den Boogaard

Research output: Chapter in Book/Report/Conference proceedingConference contributionAcademicpeer-review

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Abstract

Robust design of forming processes is gaining attention throughout the industry. To analyze the robustness of a sheet metal forming process using Finite Element (FE) simulations, an accurate input in terms of parameter variation is required. This paper presents a pragmatic, accurate and economic approach for measuring and modeling one of the main inputs, i.e. material properties and its associated scattering. For the purpose of this research, samples of 41 coils of a forming steel DX54D+Z (EN 10327:2004) from multiple batches have been collected. Fully determining the stochastic material behavior to the required accuracy for precise modeling in FE simulations would involve performing many mechanical experiments. Instead, the present work combines mechanical testing and texture analysis to limit the required effort. Moreover, use is made of the correlations between the material parameters to efficiently model the material property scatter for use in the numerical robustness analysis. The proposed approach is validated by the forming of a series of cup products using the collected material. The observed experimental scatter can be reproduced efficiently using FE simulations, demonstrating the potential of the modeling approach and robustness analysis in general.
Original languageEnglish
Title of host publicationUnknown
EditorsP. Hora
Place of PublicationZurich
Pages57-62
Publication statusPublished - 2 Jun 2013
EventIDDRG 2013 - Zurich, Switzerland
Duration: 2 Jun 20135 Jun 2013

Conference

ConferenceIDDRG 2013
CountrySwitzerland
CityZurich
Period2/06/135/06/13

Fingerprint

Metal forming
Sheet metal
Materials properties
Mechanical testing
Textures
Scattering
Economics
Steel
Industry
Experiments

Keywords

  • METIS-296642
  • IR-86236

Cite this

Wiebenga, J. H., Atzema, E. H., Atzema, E. H., Boterman, R., Abspoel, M., & van den Boogaard, A. H. (2013). Accounting for material scatter in sheet metal forming simulations. In P. Hora (Ed.), Unknown (pp. 57-62). Zurich.
Wiebenga, J.H. ; Atzema, E.H. ; Atzema, E.H. ; Boterman, R. ; Abspoel, M. ; van den Boogaard, Antonius H. / Accounting for material scatter in sheet metal forming simulations. Unknown. editor / P. Hora. Zurich, 2013. pp. 57-62
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Wiebenga, JH, Atzema, EH, Atzema, EH, Boterman, R, Abspoel, M & van den Boogaard, AH 2013, Accounting for material scatter in sheet metal forming simulations. in P Hora (ed.), Unknown. Zurich, pp. 57-62, IDDRG 2013, Zurich, Switzerland, 2/06/13.

Accounting for material scatter in sheet metal forming simulations. / Wiebenga, J.H.; Atzema, E.H.; Atzema, E.H.; Boterman, R.; Abspoel, M.; van den Boogaard, Antonius H.

Unknown. ed. / P. Hora. Zurich, 2013. p. 57-62.

Research output: Chapter in Book/Report/Conference proceedingConference contributionAcademicpeer-review

TY - GEN

T1 - Accounting for material scatter in sheet metal forming simulations

AU - Wiebenga, J.H.

AU - Atzema, E.H.

AU - Atzema, E.H.

AU - Boterman, R.

AU - Abspoel, M.

AU - van den Boogaard, Antonius H.

PY - 2013/6/2

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N2 - Robust design of forming processes is gaining attention throughout the industry. To analyze the robustness of a sheet metal forming process using Finite Element (FE) simulations, an accurate input in terms of parameter variation is required. This paper presents a pragmatic, accurate and economic approach for measuring and modeling one of the main inputs, i.e. material properties and its associated scattering. For the purpose of this research, samples of 41 coils of a forming steel DX54D+Z (EN 10327:2004) from multiple batches have been collected. Fully determining the stochastic material behavior to the required accuracy for precise modeling in FE simulations would involve performing many mechanical experiments. Instead, the present work combines mechanical testing and texture analysis to limit the required effort. Moreover, use is made of the correlations between the material parameters to efficiently model the material property scatter for use in the numerical robustness analysis. The proposed approach is validated by the forming of a series of cup products using the collected material. The observed experimental scatter can be reproduced efficiently using FE simulations, demonstrating the potential of the modeling approach and robustness analysis in general.

AB - Robust design of forming processes is gaining attention throughout the industry. To analyze the robustness of a sheet metal forming process using Finite Element (FE) simulations, an accurate input in terms of parameter variation is required. This paper presents a pragmatic, accurate and economic approach for measuring and modeling one of the main inputs, i.e. material properties and its associated scattering. For the purpose of this research, samples of 41 coils of a forming steel DX54D+Z (EN 10327:2004) from multiple batches have been collected. Fully determining the stochastic material behavior to the required accuracy for precise modeling in FE simulations would involve performing many mechanical experiments. Instead, the present work combines mechanical testing and texture analysis to limit the required effort. Moreover, use is made of the correlations between the material parameters to efficiently model the material property scatter for use in the numerical robustness analysis. The proposed approach is validated by the forming of a series of cup products using the collected material. The observed experimental scatter can be reproduced efficiently using FE simulations, demonstrating the potential of the modeling approach and robustness analysis in general.

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Wiebenga JH, Atzema EH, Atzema EH, Boterman R, Abspoel M, van den Boogaard AH. Accounting for material scatter in sheet metal forming simulations. In Hora P, editor, Unknown. Zurich. 2013. p. 57-62