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Simulation via advanced finite element method and localisation modelling for sheet forming

Objective



Objectives and content
First generation commercial numerical models such as
finite element codes are currently used in the sheet
metal forming industry to improve product quality and to
reduce development costs. The numerical formulations and
material descriptions used so far have not permitted
accurate predictions of springback, instabilities or
defects such as diffuse necking, shear bands, wrinkling
buckling, tearing failure or ears. The objective of the
proposed new research programme is to develop a new
generation of predictive finite element codes for strain
localisation in thin sheet forming based on precise
experimental observations and analyses. This requires a
fundamental study of material behaviour and localisation
phenomena, the identification localisation parameters by
analysing tests for various strain paths, the
implementation localisation criteria in finite element
formulation for thin sheet forming while developing
numerical procedures for adapting the mesh within nonlinear finite element models in order to capture the
localisation initiation and propagation.
Three metals have been selected so as to span the
spectrum of deep drawing operations for automotive
applications: a classical deep drawing steel, 1050
aluminium and a stainless steel. Specific aims of the
research programme are:
to improve existing experimental techniques to track
the propagation of instabilities at any stage of
laboratory or a process related tests,
to implement a gradient plasticity theory for thin
metal sheets,
to develop 3D adaptive remeshing techniques and a
contact algorithm for thin shell formulations,
to use these numerical models as direct models in
inverse methods in order to identify the failure modes
from forming limit tests,
to define failure modes and localisation criteria.
Detailed comparisons between experimental tests and
numerical predictions will be carried out for deep
drawing tests and for two industrial parts: an exhaust
pipe and an oil pan.
The consortium gathers materials scientists, finite
element specialists, SME software companies and a large
European industrial end-user.
The research programme conforms to Framework IV BriteEuRam objectives 1.1 (New Production Systems), 1.4
(Safety and Reliability of Production Systems), 2.1
(Materials Engineering), 2.2 (New Methods for Product
Design and Manufacturing), 2.3 (Reliability and Quality
of Materials and Products) and 3B.2 (Vehicle Production).

Coordinator

ASSOCIATION POUR LA RECHERCHE ET LE DEVELOPPEMENT DES METHODES ET PROCESSUS INDUSTRIELS
Address
Avenue Claude Daunesse Cnrs Ura 1374
06565 Valbonne
France

Participants (5)

CENTRO RICERCHE FIAT S.C.P.A.
Italy
Address
Strada Torino 50
10043 Orbassano
FINITE ELEMENT ANALYSIS LTD.
United Kingdom
Address
High Street 66
KT1 1HN Kingston Upon Thames
IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDICINE
United Kingdom
Address
Prince Consort Road
SW7 2BY London
SCIENCES & COMPUTERS CONSULTANTS SARL
France
Address
67,Rue De La Richelandière, 8-Parc Giron
42100 Saint-etienne
Technische Universiteit Delft
Netherlands
Address
134,Stevinweg 134
2600 GA Delft