Carlos Felipe Guzmán

Numerical Simulation of a Pyramid Steel Sheet Formed by Single Point Incremental Forming Using Solid-Shell Finite Elements

Single Point Incremental Forming (SPIF) is an interesting manufacturing process due to its dieless nature and its increased formability compared to conventional forming processes. Nevertheless, the process suffers from large geometric deviations when compared to the original CAD profile. One particular example arises when analyzing a truncated two-slope pyramid [. In this paper, a finite element simulation of this geometry is carried out using a newly implemented solid-shell element [, which is based on the Enhanced Assumed Strain (EAS) and the Assumed Natural Strain (ANS) techniques. The model predicts the shape of the pyramid very well, correctly representing the springback and the through thickness shear (TTS). Besides, the effects of the finite element mesh refinement, the EAS and ANS techniques on the numerical prediction are presented. It is shown that the EAS modes included in the model have a significant influence on the accuracy of the results.

Towards Fracture Prediction in Single Point Incremental Forming

The stress state in metal forming processes usually implies low values of triaxiality. It is well known that damage models based only on triaxiality fails to capture the damage behavior properly, and recent articles have stressed the effect of the Lode parameter in describing damage. Moreover, in some process like incremental forming, the through thickness shear could dominate the rupture mechanism making the description, using solely the triaxiality, inaccurate. In this paper, a preliminary study of the stress state is carried over a near-to-failure single point incremental forming (SPIF) formed cone, through finite elements simulations using a newly developed solid-shell element. The results provide a basis for further studies into damage development in SPIF.

Evaluation of the Enhanced Assumed Strain and Assumed Natural Strain in the SSH3D and RESS3 Solid Shell Elements for Single Point Incremental Forming Simulation

Single Point Incremental Forming (SPIF) is a recent sheet forming process which can give a symmetrical or asymmetrical shape by using a small tool. Without the need of dies, the SPIF is capable to deal with rapid prototyping and small batch productions at low cost. Extensive research from both experimental and numerical sides has been carried out in the last years. Recent developments in the finite element simulations for sheet metal forming have allowed new modeling techniques, such as the Solid Shell elements, which combine the main features of shell hypothesis with a solid-brick element. In this article, two recently developed elements -SSH3D element [1, 2] and RESS3 element [3]- implemented in Lagamine (finite element code developed by the ArGEnCo department of the University of Liège) are explained and evaluated using the SPIF line test. To avoid locking problems, the well-known Enhanced Assumed Strain (EAS) and Assumed Natural Strain (ANS) techniques are used. The influence of the different EAS and ANS parameters are analized comparing the predicted tool forces and the shape of a transversal cut, at the end of the process. The results show a strong influence of the EAS in the forces prediction, proving that a correct choice is fundamental for an accurate simulation of the SPIF using Solid Shell elements.

Modeling the ductile fracture and the plastic anisotropy of DC01 steel at room temperature and low strain rates

This paper presents different extensions of the classical GTN damage model implemented in a finite element code. The goal of this study is to assess these extensions for the numerical prediction of failure of a DC01 steel sheet during a single point incremental forming process, after a proper identification of the material parameters. It is shown that the prediction of failure appears too early compared to experimental results. Though, the use of the Thomason criterion permitted to delay the onset of coalescence and consequently the final failure.