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Title: Towards Efficient Modelling Of Macro And Micro Tool Deformations In Sheet Metal Forming

Abstract

During forming, the deep drawing press and tools undergo large loads, and even though they are extremely sturdy structures, deformations occur. This causes changes in the geometry of the tool surface and the gap width between the tools. The deep drawing process can be very sensitive to these deformations. Tool and press deformations can be split into two categories. The deflection of the press bed-plate or slide and global deformation in the deep drawing tools are referred to as macro press deformation. Micro-deformation occurs directly at the surfaces of the forming tools and is one or two orders lower in magnitude.The goal is to include tool deformation in a FE forming simulation. This is not principally problematic, however, the FE meshes become very large, causing an extremely large increase in numerical effort. In this paper, various methods are discussed to include tool elasticity phenomena with acceptable cost. For macro deformation, modal methods or 'deformable rigid bodies' provide interesting possibilities. Static condensation is also a well known method to reduce the number of DOFs, however the increasing bandwidth of the stiffness matrix limits this method severely, and decreased calculation times are not expected. At the moment, modeling Micro-deformation remains unfeasible. Theoretically,more » it can be taken into account, but the results may not be reliable due to the limited size of the tool meshes and due to approximations in the contact algorithms.« less

Authors:
 [1];  [2];  [3]
  1. Netherlands Institute for Metals Research, Mekelweg 2 P.O. Box 5008 2600GA Delft (Netherlands)
  2. (Germany)
  3. University of Twente, Postbus 217 7500 AE Enschede (Netherlands)
Publication Date:
OSTI Identifier:
21061748
Resource Type:
Journal Article
Resource Relation:
Journal Name: AIP Conference Proceedings; Journal Volume: 908; Journal Issue: 1; Conference: NUMIFORM 2007: 9. international conference on numerical methods in industrial forming processes, Porto (Portugal), 17-21 Jun 2007; Other Information: DOI: 10.1063/1.2740896; (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; ALGORITHMS; ALLOYS; APPROXIMATIONS; COMPUTERIZED SIMULATION; DEFORMATION; DRAWING; ELASTICITY; FINITE ELEMENT METHOD; FLEXIBILITY; METALS; PLATES; PRESSING; SHEETS

Citation Formats

Lingbeek, R. A., INPRO Innovationsgesellschaft fuer fortgeschrittene Produktionssysteme in der Fahrzeugindustrie mbH Hallerstrasse 1, D-10587 Berlin, and Meinders, T.. Towards Efficient Modelling Of Macro And Micro Tool Deformations In Sheet Metal Forming. United States: N. p., 2007. Web. doi:10.1063/1.2740896.
Lingbeek, R. A., INPRO Innovationsgesellschaft fuer fortgeschrittene Produktionssysteme in der Fahrzeugindustrie mbH Hallerstrasse 1, D-10587 Berlin, & Meinders, T.. Towards Efficient Modelling Of Macro And Micro Tool Deformations In Sheet Metal Forming. United States. doi:10.1063/1.2740896.
Lingbeek, R. A., INPRO Innovationsgesellschaft fuer fortgeschrittene Produktionssysteme in der Fahrzeugindustrie mbH Hallerstrasse 1, D-10587 Berlin, and Meinders, T.. Thu . "Towards Efficient Modelling Of Macro And Micro Tool Deformations In Sheet Metal Forming". United States. doi:10.1063/1.2740896.
@article{osti_21061748,
title = {Towards Efficient Modelling Of Macro And Micro Tool Deformations In Sheet Metal Forming},
author = {Lingbeek, R. A. and INPRO Innovationsgesellschaft fuer fortgeschrittene Produktionssysteme in der Fahrzeugindustrie mbH Hallerstrasse 1, D-10587 Berlin and Meinders, T.},
abstractNote = {During forming, the deep drawing press and tools undergo large loads, and even though they are extremely sturdy structures, deformations occur. This causes changes in the geometry of the tool surface and the gap width between the tools. The deep drawing process can be very sensitive to these deformations. Tool and press deformations can be split into two categories. The deflection of the press bed-plate or slide and global deformation in the deep drawing tools are referred to as macro press deformation. Micro-deformation occurs directly at the surfaces of the forming tools and is one or two orders lower in magnitude.The goal is to include tool deformation in a FE forming simulation. This is not principally problematic, however, the FE meshes become very large, causing an extremely large increase in numerical effort. In this paper, various methods are discussed to include tool elasticity phenomena with acceptable cost. For macro deformation, modal methods or 'deformable rigid bodies' provide interesting possibilities. Static condensation is also a well known method to reduce the number of DOFs, however the increasing bandwidth of the stiffness matrix limits this method severely, and decreased calculation times are not expected. At the moment, modeling Micro-deformation remains unfeasible. Theoretically, it can be taken into account, but the results may not be reliable due to the limited size of the tool meshes and due to approximations in the contact algorithms.},
doi = {10.1063/1.2740896},
journal = {AIP Conference Proceedings},
number = 1,
volume = 908,
place = {United States},
year = {Thu May 17 00:00:00 EDT 2007},
month = {Thu May 17 00:00:00 EDT 2007}
}