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Title: Impact Of Elastic Modulus Degradation On Springback In Sheet Metal Forming

Abstract

Strain recovery after removal of forming loads, commonly defined as springback, is of great concern in sheet metal forming, in particular with regard to proper prediction of the final shape of the part. To control the problem a lot of work has been done, either by minimizing the springback on the material side or by increasing the estimation precision in corresponding process simulations. Unfortunately, by currently available software springback still cannot be adequately predicted, because most analyses of springback are using linear, isotropic and constant Young's modulus and Poisson's ratio. But, as it was measured and reported, none of it is true. The aim of this work is to propose an upgraded mechanical model which takes evolution of damage and related orthotropic stiffness degradation into account. Damage is considered by inclusion of ellipsoidal cavities, and their influence on the stiffness degradation is taken in accordance with the Mori-Tanaka theory, adopting the GTN model for plastic flow. In order to improve the numerical springback prediction, two major things are important: first, the correct evaluation of the stress-strain state at the end of the forming process, and second, correctness of the elastic properties used in the elastic relaxation analysis. Since in modellingmore » of the forming process we adopt a damage constitutive model with orthotropic stiffness degradation considered, a corresponding damage parameters identification upon specific experimental tests data must be performed first, independently of the metal forming modelling. An improved identification of material parameters, which simultaneously considers tensile test results with different type of specimens and using neural network, is proposed. With regard to the case in which damage in material is neglected it is shown in the article how the springback of a formed part differs, when we take orthotropic damage evolution into consideration.« less

Authors:
;  [1];  [2]
  1. Laboratory for Numerical Modelling and Simulation, Faculty of Mechanical Engineering, University of Ljubljana, Ljubljana (Slovenia)
  2. Kovinoplastika Loz, Stari trg pri Lozu (Slovenia)
Publication Date:
OSTI Identifier:
21061776
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: 10.1063/1.2740929; (c) 2007 American Institute of Physics; Country of input: International Atomic Energy Agency (IAEA)
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; ALLOYS; COMPUTER CODES; COMPUTERIZED SIMULATION; ELASTICITY; FLEXIBILITY; METALS; NEURAL NETWORKS; PLASTICITY; POISSON RATIO; SHEETS; STRAINS; STRESSES; YOUNG MODULUS

Citation Formats

Halilovic, Miroslav, Stok, Boris, and Vrh, Marko. Impact Of Elastic Modulus Degradation On Springback In Sheet Metal Forming. United States: N. p., 2007. Web. doi:10.1063/1.2740929.
Halilovic, Miroslav, Stok, Boris, & Vrh, Marko. Impact Of Elastic Modulus Degradation On Springback In Sheet Metal Forming. United States. doi:10.1063/1.2740929.
Halilovic, Miroslav, Stok, Boris, and Vrh, Marko. Thu . "Impact Of Elastic Modulus Degradation On Springback In Sheet Metal Forming". United States. doi:10.1063/1.2740929.
@article{osti_21061776,
title = {Impact Of Elastic Modulus Degradation On Springback In Sheet Metal Forming},
author = {Halilovic, Miroslav and Stok, Boris and Vrh, Marko},
abstractNote = {Strain recovery after removal of forming loads, commonly defined as springback, is of great concern in sheet metal forming, in particular with regard to proper prediction of the final shape of the part. To control the problem a lot of work has been done, either by minimizing the springback on the material side or by increasing the estimation precision in corresponding process simulations. Unfortunately, by currently available software springback still cannot be adequately predicted, because most analyses of springback are using linear, isotropic and constant Young's modulus and Poisson's ratio. But, as it was measured and reported, none of it is true. The aim of this work is to propose an upgraded mechanical model which takes evolution of damage and related orthotropic stiffness degradation into account. Damage is considered by inclusion of ellipsoidal cavities, and their influence on the stiffness degradation is taken in accordance with the Mori-Tanaka theory, adopting the GTN model for plastic flow. In order to improve the numerical springback prediction, two major things are important: first, the correct evaluation of the stress-strain state at the end of the forming process, and second, correctness of the elastic properties used in the elastic relaxation analysis. Since in modelling of the forming process we adopt a damage constitutive model with orthotropic stiffness degradation considered, a corresponding damage parameters identification upon specific experimental tests data must be performed first, independently of the metal forming modelling. An improved identification of material parameters, which simultaneously considers tensile test results with different type of specimens and using neural network, is proposed. With regard to the case in which damage in material is neglected it is shown in the article how the springback of a formed part differs, when we take orthotropic damage evolution into consideration.},
doi = {10.1063/1.2740929},
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}
}
  • Strain recovery after removal of forming loads, commonly defined as springback, is of great concern in sheet metal forming, in particular with regard to proper prediction of the final shape of the part. To control the problem a lot of work has been done, either by minimizing the springback on the material side or by increasing the estimation precision in corresponding process simulations. Unfortunately, by currently available software springback still cannot be adequately predicted, because most analyses of springback are using linear, isotropic and constant Young's modulus and Poisson's ratio. But, as it was measured and reported, none of itmore » is true. The aim of this work is to propose an upgraded mechanical model which takes evolution of damage and related orthotropic stiffness degradation into account. Damage is considered by inclusion of ellipsoidal cavities, and their influence on the stiffness degradation is taken in accordance with the Mori-Tanaka theory, adopting the GTN model for plastic flow. With regard to the case in which damage in material is neglected it is shown in the article how the springback of a formed part differs, when we take orthotropic damage evolution into consideration.« less
  • In terms of the intensive similarity between the sheet metal forming-springback process and that of the annealing of metals, it is suggested that the simulation of the sheet metal forming process is performed with the Nonlinear FEM and the springback prediction is implemented by solving the large-scale combinational optimum problem established on the base of the energy descending and balancing in deformed part. The BFGS-SA hybrid SA approach is proposed to solve this problem and improve the computing efficiency of the traditional SA and its capability of obtaining the global optimum solution. At the same time, the correlative annealing strategiesmore » for the SA algorithm are determined in here. By comparing the calculation results of sample part with those of experiment measurement at the specified sections, the rationality of the schedule of springback prediction used and the validity of the BFGS-SA algorithm proposed are verified.« less
  • Springback is an unquenchable forming defect in the sheet metal forming process. How to calculate springback accurately is a big challenge for a lot of FEA software. Springback compensation makes the stamped final part accordant with the designed part shape by modifying tool surface, which depends on the accurate springback amount. How ever, the meshing data based on numerical simulation is expressed by nodes and elements, such data can not be supplied directly to tool surface CAD data. In this paper, a tool surface compensation algorithm based on numerical simulation technique of springback process is proposed in which the independentlymore » developed dynamic explicit springback algorithm (DESA) is used to simulate springback amount. When doing the tool surface compensation, the springback amount of the projected point can be obtained by interpolation of the springback amount of the projected element nodes. So the modified values of tool surface can be calculated reversely. After repeating the springback and compensation calculations for 1{approx}3 times, the reasonable tool surface mesh is gained. Finally, the FEM data on the compensated tool surface is fitted into the surface by CAD modeling software. The examination of a real industrial part shows the validity of the present method.« less
  • In this paper the application of a crystal plasticity model for body-centered cubic crystals in the simulation of a sheet metal forming process is discussed. The material model parameters are identified by a combination of a texture approximation procedure and a conventional parameter identification scheme. In the application of a cup drawing process the model shows an improvement of the strain and earing prediction as well as the qualitative springback results in comparison with a conventional phenomenological model.
  • In the sheet metal forming simulation, the shell element widely used is assumed as a plane stress state based on the Mindlin-Reissner theory. Numerical prediction with the conventional shell element is not accurate when the bending radius is small compared to the sheet thickness. The main reason is because the strain and stress formulation of the conventional shell element does not fit the actual phenomenon. In order to predict precisely the springback of a bent sheet with a severe bend, a measurement method for through-thickness strain has been proposed. The strain was formulated based on measurement results and calculation resultsmore » from solid element. Through-thickness stress distribution was formulated based on the equilibrium. The proposed shell element based on the formulations was newly introduced into the FEM code. The accuracy of this method's prediction of the springback shape of two bent processes has been confirmed. As a result, it was found that the springback shape even in severe bending can be predicted with high accuracy. Moreover, the calculation time in the proposed shell element is about twice that in the conventional shell element, and has been shortened to about 1/20 compared to a solid element.« less