Numerical forming simulations and optimisation in advanced materials

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Abstract

With the introduction of new materials as high strength steels, metastable steels and fibre reinforced composites, the need for advanced physically valid constitutive models arises. In finite deformation problems constitutive relations are commonly formulated in terms the Cauchy stress as a function of the elastic Finger tensor and an objective rate of the Cauchy stress as a function of the rate of deformation tensor. For isotropic materials models this is rather straightforward, but for anisotropic material models, including elastic anisotropy as well as plastic anisotropy, this may lead to confusing formulations. It will be shown that it is more convenient to define the constitutive relations in terms of invariant tensors referred to the deformed metric. Experimental results are presented that show new combinations of strain rate and strain path sensitivity. An adaptive through- thickness integration scheme for plate elements is developed, which improves the accuracy of spring back prediction at minimal costs. A procedure is described to automatically compensate the CAD tool shape numerically to obtain the desired product shape. Forming processes need to be optimized for cost saving and product improvement. Until recently, a trial-and-error process in the factory primarily did this optimization. An optimisation strategy is proposed that assists an engineer to model an optimization problem that suits his needs, including an efficient algorithm for solving the problem.
Original languageEnglish
Title of host publicationMaterials processing and design: modeling, simulation and applications
Subtitle of host publicationNUMIFORM '07 : proceedings of the 9th International Conference on Numerical Methods in Industrial Forming Processes, Porto, Portugal, 17-21 June, 2007
EditorsJ.M.A. César de Sá, Abel D. Santos
Place of PublicationMelville, NY
PublisherAmerican Institute of Physics
Pages281-286
ISBN (Electronic)978-0-7354-0416-8
ISBN (Print)978-0-7354-0415-1
Publication statusPublished - 2007
Event9th International Conference on Numerical Methods in Industrial Forming Processes, NUMIFORM 2007 - Porto, Portugal
Duration: 17 Jun 200721 Jun 2007
Conference number: 9

Publication series

NameAIP Conference Proceedings
PublisherAIP
Number1
Volume908
ISSN (Print)0094-243X

Conference

Conference9th International Conference on Numerical Methods in Industrial Forming Processes, NUMIFORM 2007
Abbreviated titleNUMIFORM
CountryPortugal
CityPorto
Period17/06/0721/06/07

Fingerprint

optimization
tensors
simulation
plastic anisotropy
costs
elastic anisotropy
high strength steels
products
computer aided design
engineers
strain rate
steels
formulations
fibers
sensitivity
predictions

Keywords

  • Finite element
  • Anisotropy
  • Advanced materials
  • Objectivity
  • Invariance
  • Sheet metal
  • Optimisation

Cite this

Huetink, J., van den Boogaard, A. H., Geijselaers, H. J. M., & Meinders, T. (2007). Numerical forming simulations and optimisation in advanced materials. In J. M. A. César de Sá, & A. D. Santos (Eds.), Materials processing and design: modeling, simulation and applications: NUMIFORM '07 : proceedings of the 9th International Conference on Numerical Methods in Industrial Forming Processes, Porto, Portugal, 17-21 June, 2007 (pp. 281-286). (AIP Conference Proceedings; Vol. 908, No. 1). Melville, NY: American Institute of Physics.
Huetink, J. ; van den Boogaard, A.H. ; Geijselaers, H.J.M. ; Meinders, T. / Numerical forming simulations and optimisation in advanced materials. Materials processing and design: modeling, simulation and applications: NUMIFORM '07 : proceedings of the 9th International Conference on Numerical Methods in Industrial Forming Processes, Porto, Portugal, 17-21 June, 2007. editor / J.M.A. César de Sá ; Abel D. Santos. Melville, NY : American Institute of Physics, 2007. pp. 281-286 (AIP Conference Proceedings; 1).
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keywords = "Finite element, Anisotropy, Advanced materials, Objectivity, Invariance, Sheet metal, Optimisation",
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Huetink, J, van den Boogaard, AH, Geijselaers, HJM & Meinders, T 2007, Numerical forming simulations and optimisation in advanced materials. in JMA César de Sá & AD Santos (eds), Materials processing and design: modeling, simulation and applications: NUMIFORM '07 : proceedings of the 9th International Conference on Numerical Methods in Industrial Forming Processes, Porto, Portugal, 17-21 June, 2007. AIP Conference Proceedings, no. 1, vol. 908, American Institute of Physics, Melville, NY, pp. 281-286, 9th International Conference on Numerical Methods in Industrial Forming Processes, NUMIFORM 2007, Porto, Portugal, 17/06/07.

Numerical forming simulations and optimisation in advanced materials. / Huetink, J.; van den Boogaard, A.H.; Geijselaers, H.J.M.; Meinders, T.

Materials processing and design: modeling, simulation and applications: NUMIFORM '07 : proceedings of the 9th International Conference on Numerical Methods in Industrial Forming Processes, Porto, Portugal, 17-21 June, 2007. ed. / J.M.A. César de Sá; Abel D. Santos. Melville, NY : American Institute of Physics, 2007. p. 281-286 (AIP Conference Proceedings; Vol. 908, No. 1).

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

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T1 - Numerical forming simulations and optimisation in advanced materials

AU - Huetink, J.

AU - van den Boogaard, A.H.

AU - Geijselaers, H.J.M.

AU - Meinders, T.

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N2 - With the introduction of new materials as high strength steels, metastable steels and fibre reinforced composites, the need for advanced physically valid constitutive models arises. In finite deformation problems constitutive relations are commonly formulated in terms the Cauchy stress as a function of the elastic Finger tensor and an objective rate of the Cauchy stress as a function of the rate of deformation tensor. For isotropic materials models this is rather straightforward, but for anisotropic material models, including elastic anisotropy as well as plastic anisotropy, this may lead to confusing formulations. It will be shown that it is more convenient to define the constitutive relations in terms of invariant tensors referred to the deformed metric. Experimental results are presented that show new combinations of strain rate and strain path sensitivity. An adaptive through- thickness integration scheme for plate elements is developed, which improves the accuracy of spring back prediction at minimal costs. A procedure is described to automatically compensate the CAD tool shape numerically to obtain the desired product shape. Forming processes need to be optimized for cost saving and product improvement. Until recently, a trial-and-error process in the factory primarily did this optimization. An optimisation strategy is proposed that assists an engineer to model an optimization problem that suits his needs, including an efficient algorithm for solving the problem.

AB - With the introduction of new materials as high strength steels, metastable steels and fibre reinforced composites, the need for advanced physically valid constitutive models arises. In finite deformation problems constitutive relations are commonly formulated in terms the Cauchy stress as a function of the elastic Finger tensor and an objective rate of the Cauchy stress as a function of the rate of deformation tensor. For isotropic materials models this is rather straightforward, but for anisotropic material models, including elastic anisotropy as well as plastic anisotropy, this may lead to confusing formulations. It will be shown that it is more convenient to define the constitutive relations in terms of invariant tensors referred to the deformed metric. Experimental results are presented that show new combinations of strain rate and strain path sensitivity. An adaptive through- thickness integration scheme for plate elements is developed, which improves the accuracy of spring back prediction at minimal costs. A procedure is described to automatically compensate the CAD tool shape numerically to obtain the desired product shape. Forming processes need to be optimized for cost saving and product improvement. Until recently, a trial-and-error process in the factory primarily did this optimization. An optimisation strategy is proposed that assists an engineer to model an optimization problem that suits his needs, including an efficient algorithm for solving the problem.

KW - Finite element

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KW - Objectivity

KW - Invariance

KW - Sheet metal

KW - Optimisation

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SN - 978-0-7354-0415-1

T3 - AIP Conference Proceedings

SP - 281

EP - 286

BT - Materials processing and design: modeling, simulation and applications

A2 - César de Sá, J.M.A.

A2 - Santos, Abel D.

PB - American Institute of Physics

CY - Melville, NY

ER -

Huetink J, van den Boogaard AH, Geijselaers HJM, Meinders T. Numerical forming simulations and optimisation in advanced materials. In César de Sá JMA, Santos AD, editors, Materials processing and design: modeling, simulation and applications: NUMIFORM '07 : proceedings of the 9th International Conference on Numerical Methods in Industrial Forming Processes, Porto, Portugal, 17-21 June, 2007. Melville, NY: American Institute of Physics. 2007. p. 281-286. (AIP Conference Proceedings; 1).