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Title: Sheet Metal Stamping Analysis and Process Design based on the Inverse Approach

Abstract

The simplified (one step) method also called 'inverse approach' (IA) for the numerical analysis of the stamping process has been continuously developed by the authors since the end of the eighties (1, 2, 3, 4). In the present paper we recall the main finite element formulation aspects of a robust IA analysis code, called FAST{sub S}TAMP, for an efficient estimation of the large elastoplastic strains (in particular the thickness strains) encountered in deep drawing operations. Our results will be presented and compared with others, obtained either from experiments or from incremental codes such as ABAQUS or STAMPACK. The presentation includes 'math based' optimization algorithms and strategies for process parameter design. The cost functions and constraints are mainly express to reduce or control the thickness changes, the localized necking, the wrinkling tendency, the springback effects after forming. The design variables are describing the shape of the blank and the tools, the restraining forces due to drawbeads, material properties such as anisotropy coefficient and hardening exponent. Results will be presented to show the actual capabilities of the coupled analysis and optimization strategy with application to the design of stamping parameters.

Authors:
;  [1];  [2]
  1. Universite de Technologie de Compiegne, BP 60319, 60203 Compiegne (France)
  2. Universite de Reims Champagne-Ardenne, BP 1039, 51687 Reims (France)
Publication Date:
OSTI Identifier:
21056997
Resource Type:
Journal Article
Resource Relation:
Journal Name: AIP Conference Proceedings; Journal Volume: 907; Journal Issue: 1; Conference: 10. ESAFORM conference on material forming, Zaragoza (Spain), 18-20 Apr 2007; Other Information: DOI: 10.1063/1.2729719; (c) 2007 American Institute of Physics; Country of input: International Atomic Energy Agency (IAEA)
Country of Publication:
United States
Language:
English
Subject:
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSICS; A CODES; ALGORITHMS; ALLOYS; ANISOTROPY; CONTROL; DESIGN; DRAWING; FINITE ELEMENT METHOD; HARDENING; METALS; NUMERICAL ANALYSIS; OPTIMIZATION; S CODES; STRAINS; THICKNESS

Citation Formats

Batoz, Jean-Louis, Naceur, Hakim, and Guo Yingqiao. Sheet Metal Stamping Analysis and Process Design based on the Inverse Approach. United States: N. p., 2007. Web. doi:10.1063/1.2729719.
Batoz, Jean-Louis, Naceur, Hakim, & Guo Yingqiao. Sheet Metal Stamping Analysis and Process Design based on the Inverse Approach. United States. doi:10.1063/1.2729719.
Batoz, Jean-Louis, Naceur, Hakim, and Guo Yingqiao. Sat . "Sheet Metal Stamping Analysis and Process Design based on the Inverse Approach". United States. doi:10.1063/1.2729719.
@article{osti_21056997,
title = {Sheet Metal Stamping Analysis and Process Design based on the Inverse Approach},
author = {Batoz, Jean-Louis and Naceur, Hakim and Guo Yingqiao},
abstractNote = {The simplified (one step) method also called 'inverse approach' (IA) for the numerical analysis of the stamping process has been continuously developed by the authors since the end of the eighties (1, 2, 3, 4). In the present paper we recall the main finite element formulation aspects of a robust IA analysis code, called FAST{sub S}TAMP, for an efficient estimation of the large elastoplastic strains (in particular the thickness strains) encountered in deep drawing operations. Our results will be presented and compared with others, obtained either from experiments or from incremental codes such as ABAQUS or STAMPACK. The presentation includes 'math based' optimization algorithms and strategies for process parameter design. The cost functions and constraints are mainly express to reduce or control the thickness changes, the localized necking, the wrinkling tendency, the springback effects after forming. The design variables are describing the shape of the blank and the tools, the restraining forces due to drawbeads, material properties such as anisotropy coefficient and hardening exponent. Results will be presented to show the actual capabilities of the coupled analysis and optimization strategy with application to the design of stamping parameters.},
doi = {10.1063/1.2729719},
journal = {AIP Conference Proceedings},
number = 1,
volume = 907,
place = {United States},
year = {Sat Apr 07 00:00:00 EDT 2007},
month = {Sat Apr 07 00:00:00 EDT 2007}
}
  • Sheet metal stamping is one of the most commonly used manufacturing processes, and hence, much research has been carried for economic gain. Searching through the literatures, however, it is found that there are still a lots of problems unsolved. For example, it is well known that for a same press, same workpiece material, and same set of die, the product quality may vary owing to a number of factors, such as the inhomogeneous of the workpice material, the loading error, the lubrication, and etc. Presently, few seem able to predict the quality variation, not to mention what contribute to themore » quality variation. As a result, trial-and-error is still needed in the shop floor, causing additional cost and time delay. This paper introduces a new approach to predict the product quality variation and identify the sensitive design / process parameters. The new approach is based on a combination of inverse Finite Element Modeling (FEM) and Monte Carlo Simulation (more specifically, the Latin Hypercube Sampling (LHS) approach). With an acceptable accuracy, the inverse FEM (also called one-step FEM) requires much less computation load than that of the usual incremental FEM and hence, can be used to predict the quality variations under various conditions. LHS is a statistical method, through which the sensitivity analysis can be carried out. The result of the sensitivity analysis has clear physical meaning and can be used to optimize the die design and / or the process design. Two simulation examples are presented including drawing a rectangular box and drawing a two-step rectangular box.« less
  • Sheet metal stamping processes have been widely implemented in many industries due to its repeatability and productivity. In general, the simulations for a sheet metal forming process involve nonlinearity, complex material behavior and tool-material interaction. Instabilities in terms of tearing and wrinkling are major concerns in many sheet metal stamping processes. In this work, a sheet metal stamping process of a mild steel for a wheelhouse used in automobile industry is studied by using an explicit nonlinear finite element code and incorporating failure analysis (tearing and wrinkling) and design under uncertainty. Margins of tearing and wrinkling are quantitatively defined viamore » stress-based criteria for system-level design. The forming process utilizes drawbeads instead of using the blank holder force to restrain the blank. The main parameters of interest in this work are friction conditions, drawbead configurations, sheet metal properties, and numerical errors. A robust design model is created to conduct a probabilistic design, which is made possible for this complex engineering process via an efficient uncertainty propagation technique. The method called the weighted three-point-based method estimates the statistical characteristics (mean and variance) of the responses of interest (margins of failures), and provide a systematic approach in designing a sheet metal forming process under the framework of design under uncertainty.« less
  • This paper employs an inverse approach (IA) formulation for the analysis of tubes under free hydroforming conditions. The IA formulation is derived from that of Guo et al. established for flat sheet hydroforming analysis using constant strain triangular membrane elements. At first, an incremental analysis of free hydroforming for a hot-dip galvanized (HG/Z140) DP600 tube is performed using the finite element Marc code. The deformed geometry obtained at the last converged increment is then used as the final configuration in the inverse analysis. This comparative study allows us to assess the predicting capability of the inverse analysis. The results willmore » be compared with the experimental values determined by Asnafi and Skogsgardh. After that, a procedure based on a forming limit diagram (FLD) is proposed to adjust the process parameters such as the axial feed and internal pressure. Finally, the adjustment process is illustrated through a re-analysis of the same tube using the inverse approach« less
  • One main influence on the dimensional accuracy in robot based incremental sheet metal forming results from the compliance of the involved robot structures. Compared to conventional machine tools the low stiffness of the robot's kinematic results in a significant deviation of the planned tool path and therefore in a shape of insufficient quality. To predict and compensate these deviations offline, a model based approach, consisting of a finite element approach, to simulate the sheet forming, and a multi body system, modeling the compliant robot structure, has been developed. This paper describes the implementation and experimental verification of the multi bodymore » system model and its included compensation method.« less
  • An efficient integration algorithm for continuum damage based elastoplastic constitutive equations is implemented in LS-DYNA. The isotropic damage parameter is defined as the ratio of the damaged surface area over the total cross section area of the representative volume element. This parameter is incorporated into the integration algorithm as an internal variable. The developed damage model is then implemented in the FEM code LS-DYNA as user material subroutine (UMAT). Pure stretch experiments of a hemispherical punch are carried out for copper sheets and the results are compared against the predictions of the implemented damage model. Evaluation of damage parameters ismore » carried out and the optimized values that correctly predicted the failure in the sheet are reported. Prediction of failure in the numerical analysis is performed through element deletion using the critical damage value. The set of failure parameters which accurately predict the failure behavior in copper sheets compared to experimental data is reported as well.« less