Laurent Duchene

Analysis of Texture Evolution and hardening Behavior during Deep drawing with an improved mixed type FEM Element

In the present study, deep drawing simulations were investigated using a recently developed mixed type finite element (FE): the BWD3D. The main formulation of the element is described, with particular focus on the shear locking treatment. Two hardening models used in the presented simulations are described: the isotropic Swift’s model and the physically based microstructural Teodosiu and Hu model. Finally, deep drawing results, in terms of earing profile, are compared to experiment. Special attention is paid to the effects of texture evolution and hardening models; the method used to implement Teodosiu and Hu hardening model is also discussed.

New Solid-Shell Finite Element Based on EAS and ANS Concepts for Sheet Metal Forming

We present in this paper a new eight node solid-shell finite element called SSH3D (Three Dimensional Solid-Shell). This element is currently implemented in the frame of the in-house research code called LAGAMINE. Here the Enhanced Assumed Strain (EAS) technique based on the Hu-Washizu variational principle, described in [1] and [2], is used to cure the volumetric locking occurring when the material shows nearly incompressible behavior and Poisson’s thickness locking caused by the high aspect ratio of the finite element. In the proposed element, the EAS technique can be combined with the Assumed Natural Strain (ANS) [3-5] concept to treat shear locking caused by the transverse shear strain and curvature thickness locking caused by the transverse normal strain. Different schemes for the ANS concept are implemented while the number of integration points and the number of EAS modes are element parameters (the element uses four integration points in the plane of the element and at least two integration points through the thickness direction in a single element layer). These features must be adjusted by the user according to the studied process (geometry and loading) so as to avoid locking and limit the calculation time. This element was successfully tested and the numerical remedies were verified using several kinds of patch tests. A double sided contact problem is modeled in order to investigate the performance and accuracy of the developed element and to validate the suggested approach.

Validation of a new finite element for incremental forming simulation using a dynamic explicit approach

Abstract: A new method for modeling the contact between the tool and the metal sheet for the incremental forming process was developed based on a dynamic explicit time integration scheme. The main advantage of this method is that it uses the actual contact location instead of fixed positions, e.g. integration or nodal points. The purpose of this article is to compare the efficiency of the new method, as far as accuracy and computation time are concerned, with finite element simulations using a classic static implicit approach. In addition, a sensitivity analysis of the mesh density will show that bigger elements can be used with the new method compared to those used in classic simulations.

Experimental characterization and constitutive modeling of TA6V mechanical behavior in plane strain state at room temperature

This paper presents an experimental and theoretical study of the quasi‐static behavior of TA6V titanium alloy in plane strain state. In order to quantify the anisotropy of the material, tests were carried out at room temperature on specimens cut out from a sheet along three loading directions. The initial yield locus is described by the phenomenological CPB06ex3 criterion and Voce’s type isotropic hardening is used. Finite element simulations are performed and compared with the experiments.

Single point incremental forming simulation with adaptive remeshing technique using solid-shell elements

Purpose – Numerical simulation of the single point incremental forming (SPIF) processes can be very demanding and time consuming due to the constantly changing contact conditions between the tool and the sheet surface, as well as the nonlinear material behaviour combined with non-monotonic strain paths. The purpose of this paper is to propose an adaptive remeshing technique implemented in the in-house implicit finite element code LAGAMINE, to reduce the simulation time. This remeshing technique automatically refines only a portion of the sheet mesh in vicinity of the tool, therefore following the tool motion. As a result, refined meshes are avoided and consequently the total CPU time can be drastically reduced. Design/methodology/approach – SPIF is a dieless manufacturing process in which a sheet is deformed by using a tool with a spherical tip. This dieless feature makes the process appropriate for rapid-prototyping and allows for an innovative possibility to reduce overall costs for small batches, since...

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.

Model identification and FE simulations: Effect of different yield loci and hardening laws in sheet forming

The bi‐axial experimental equipment developed by Flores enables to perform Baushinger shear tests and successive or simultaneous simple shear tests and plane‐strain tests. Such experiments and classical tensile tests investigate the material behavior in order to identify the yield locus and the hardening models. With tests performed on two steel grades, the methods applied to identify classical yield surfaces such as Hill or Hosford ones as well as isotropic Swift type hardening or kinematic Armstrong‐Frederick hardening models are explained. Comparison with the Taylor‐Bishop‐Hill yield locus is also provided. The effect of both yield locus and hardening model choice will be presented for two applications: Single Point Incremental Forming (SPIF) and a cup deep drawing.

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.

Material parameter identification of Cazacu's model for Ti6Al4V using the simulated annealing algorithm

Phenomenological yield criteria are generally described by many material parameters. A technique to identify these parameters is required to find the best fit to the results of the mechanical tests. The parameter identification by the classical simulated annealing technique is presented in this paper. This algorithm, based on works by Metropolis et al, is a global optimization method that distinguishes between different local optima to reach the global optimum. The anisotropic model used in this study is the one proposed by Cazacu et al. To prove the efficiency of the proposed algorithm, the material parameters of Ti6Al4V titanium alloy are identified and compared with those obtained using different identification procedures and the same experimental data.

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.