FEM simulation of multi step forming of thick sheet

H.H. Wisselink, J. Huetink

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

    Abstract

    A case study has been performed on the forming of an industrial product. This product, a bracket, is made of 5mm thick sheet in multiple steps. The process exists of a bending step followed by a drawing and a flanging step. FEM simulations have been used to investigate this forming process.
    First, it has been investigated on a representative section whether shell elements can still be used for a small curvature thickness ratio. The difference between solid and shell elements proved to be acceptable, so shell elements have been used in the subsequent work.
    The next topic that will be addressed is the simulation of the combination of two forming steps. The springback of the sheet after the bending step is calculated and the results are transferred as initial condition to the next drawing simulation. Implicit dynamics and gravity are needed for the simulation of the closing of the curved blankholder with a curved product. Element refinement is used, as the radii of the tools in the drawing step are much smaller than in the bending step.
    From practice it is known that this product does not fail by necking during drawing but fails at the product radius. Therefore the commonly used FLD in sheet metal forming cannot be used here. Instead fracture criteria are used to assess the failure of this product. A tool modification shows how this forming process can be influenced.
    Original languageEnglish
    Title of host publicationMaterials processing and design : modeling, simulation and applications
    Subtitle of host publicationNUMIFORM 2004 : proceedings of the 8th International Conference on Numerical Methods in Industrial Forming Processes
    EditorsSomnath Chosh, Jose M. Castro, June K. Lee
    Place of PublicationMelville, NY
    PublisherAmerican Institute of Physics
    Pages899-904
    ISBN (Electronic)0-7354-0189-6
    ISBN (Print)0-7354-0188-8
    DOIs
    Publication statusPublished - 13 Jun 2004
    Event8th International Conference on Numerical Methods in Industrial Forming Processes, NUMIFORM 2004 - Columbus, United States
    Duration: 13 Jun 200417 Jun 2004
    Conference number: 8

    Publication series

    NameAIP Conference Proceedings
    PublisherAIP
    Volume712
    ISSN (Print)0094-243X

    Conference

    Conference8th International Conference on Numerical Methods in Industrial Forming Processes, NUMIFORM 2004
    Abbreviated titleNUMIFORM
    CountryUnited States
    CityColumbus
    Period13/06/0417/06/04

    Fingerprint Dive into the research topics of 'FEM simulation of multi step forming of thick sheet'. Together they form a unique fingerprint.

  • Cite this

    Wisselink, H. H., & Huetink, J. (2004). FEM simulation of multi step forming of thick sheet. In S. Chosh, J. M. Castro, & J. K. Lee (Eds.), Materials processing and design : modeling, simulation and applications: NUMIFORM 2004 : proceedings of the 8th International Conference on Numerical Methods in Industrial Forming Processes (pp. 899-904). (AIP Conference Proceedings; Vol. 712). Melville, NY: American Institute of Physics. https://doi.org/10.1063/1.1766641