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Adaptive 2D finite element simulation of metal forming processes
Author(s) -
Yang Henry T. Y.,
Heinstein Martin,
Shih J.M.
Publication year - 1989
Publication title -
international journal for numerical methods in engineering
Language(s) - English
Resource type - Journals
SCImago Journal Rank - 1.421
H-Index - 168
eISSN - 1097-0207
pISSN - 0029-5981
DOI - 10.1002/nme.1620280612
Subject(s) - finite element method , plane stress , rotational symmetry , extrusion , forming processes , mechanical engineering , process (computing) , computer simulation , mesh generation , plane (geometry) , stress (linguistics) , thermal , structural engineering , adaptive mesh refinement , computer science , materials science , engineering , mechanics , geometry , computational science , mathematics , composite material , simulation , physics , linguistics , philosophy , meteorology , operating system
The development and integration of available current methods and the development of new methods for an adaptive finite element analysis of metal forming processes are presented. The analysis includes large‐strain, elastic–plastic, and thermal effects. Many numerical methods such as mesh generation, simulation of the contact between the workpiece and tool and die, and optimization of the finite element mesh are integrated and incorporated. In addition, an algorithm is developed which can detect certain severely distorted elements where the area of integration is approaching zero. The advantage of correcting these regions of locally distorted elements is demonstrated. These numerical methods are implemented in a finite element program developed for simulating metal forming processes, with the emphasis on automating the analysis. Examples include an axisymmetric stress simulation of a coldheading process, a plane strain simulation of an extrusion process and a plane strain simulation of orthogonal metal cutting, all with noticeable thermal effects. The orthogonal cutting forces and feed forces calculated are compared with two sets of experimental data, with good agreement.