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Modelling and Simulation of Sheet Metal Forming Processes

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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (31 August 2019) | Viewed by 63269

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Special Issue Editors

Prof. Dr. Marta Oliveira

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Guest Editor

Centre for Mechanical Engineering, Materials and Processes (CEMMPRE), University of Coimbra, 3030-788 Coimbra, Portugal
Interests: applied and computational mechanics; sheet metal forming processes; numerical simulation; constitutive modelling; contact with friction problems; optimization techniques and algorithms

Prof. Dr. José Valdemar Fernandes

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Guest Editor

Centre for Mechanical Engineering, Materials and Processes (CEMMPRE), University of Coimbra, 3030-788 Coimbra, Portugal
Interests: large plastic deformations; inverse analysis; applications to metal forming; material parameters identification; modeling and mechanical behaviour of carbon nanotubes
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Dear Colleagues,

In the mid-1970s, B. Budiansky expressed his dream: “I imagined a black box—a black computation box that was incredibly powerful and into which we could feed a mathematical description of what the stylists envisioned for a certain sheet metal shape. Then push a button and the computer spits out the die shape, the blank configuration needed, the draw beads and their orientation and configuration. If it is not possible, it tells us that too! […]. Even if it is possible, perhaps that's not enough information, and so the computer will give us the probability of success, if we have fed in variabilities in thicknesses, moduli, shapes of stress-strain relations, and so on.” (in: Mechanics of Sheet Metal—Material Behavior and Deformation Analysis, Koistinen and Wang , Eds., Plenum Press, 1978).

This challenge involves continuous developments in different areas, such as: (i) constitutive modelling, including hardening, anisotropy and damage; (ii) friction modelling; (iii) failure criteria; (iv) strategies for parameters identification of constitutive, friction and failure models; (v) numerical models for description of the contact with friction conditions, including deformable tools; (vi) numerical strategies for the analysis of multistep sheet metal forming processes; (vii) optimization procedures combined with numerical simulation, to define forming process parameters; (viii) numerical simulation combined with statistical analysis tools; and (ix) application to novel sheet metal forming processes and materials, such as warm forming and multi-layer sheets.

The aim of this Special Issue is to collect full papers, communications and reviews, about modeling and numerical simulation of sheet metal forming processes, which may contribute to bridge the gap between dream and virtual reality.

Prof. Marta Oliveira
Prof. José Valdemar Fernandes
Guest Editors

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Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

Numerical simulation
Modeling
Hardening
Anisotropy
Parameters identification
Inverse analysis
Damage
Mechanical properties
Application to sheet metal forming

Published Papers (14 papers)

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Editorial

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5 pages, 196 KiB

Open AccessEditorial

Modelling and Simulation of Sheet Metal Forming Processes

by Marta C. Oliveira and José V. Fernandes

Metals 2019, 9(12), 1356; https://doi.org/10.3390/met9121356 - 17 Dec 2019

Cited by 9 | Viewed by 3050

Abstract

Numerical simulation of sheet metal forming processes has become an indispensable tool for the design of components and their forming process, in industries ranging from the automotive, to the aeronautics, packing and household appliances [...] Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

Research

Jump to: Editorial

16 pages, 4666 KiB

Open AccessArticle

Physical Modelling and Numerical Simulation of the Deep Drawing Process of a Box-Shaped Product Focused on Material Limits Determination

by Miroslav Tomáš, Emil Evin, Ján Kepič and Juraj Hudák

Metals 2019, 9(10), 1058; https://doi.org/10.3390/met9101058 - 28 Sep 2019

Cited by 12 | Viewed by 4383

Abstract

Similitude theory helps engineers and scientists to accurately predict the behaviors of real systems through the application of scaling laws to the experimental results of a scale model related to the real system by similarity conditions. The theory was applied when studying the deep drawing process of a bathtub made from cold rolled low carbon aluminum-killed steel from the point of view of material limits. The bathtub model was created on the basis of geometric, physical, and mechanical similarity on a scale of 1:5. Thus, simulations and physical models were created. The simulation model was used to verify the combination yield locus/hardening law on the basis of comparing the thickness change. As a result, Hill 48/Krupkowski showed the minimal deviation by comparing data evaluated from numerical simulations and that measured on the physical model. Additionally, material anisotropy was modelled when virtual materials were defined from experimentally measured values of the plastic strain ratio. As an outcome, extra deep drawing quality steel with an average plastic strain ratio of r_m ≥ 1.47 and an average strain hardening exponent of n_m ≥ 0.23 must be used for the deep drawing of the bathtub. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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22 pages, 9355 KiB

Open AccessArticle

Numerical Study on the Formability of Metallic Bipolar Plates for Proton Exchange Membrane (PEM) Fuel Cells

by Diogo M. Neto, Marta C. Oliveira, José L. Alves and Luís F. Menezes

Metals 2019, 9(7), 810; https://doi.org/10.3390/met9070810 - 23 Jul 2019

Cited by 23 | Viewed by 8002

Abstract

Thin stamped bipolar plates (BPPs) are viewed as promising alternatives to traditional graphite BPPs in proton exchange membrane fuel cells. Metallic BPPs provide good thermal/electrical conductivity and exhibit high mechanical strength, to support the loads within the stack. However, BPPs manufactured by stamping processes are prone to defects. In this study, the effect of the tool’s geometry on the thin sheet formability is investigated through finite element simulation. Despite the broad variety of flow field designs, most of BPPs comprise two representative zones. Hence, in order to reduce the computational cost, the finite element analysis is restricted to these two zones, where the deformation induced by the stamping tools is investigated. The channel/rib width, the punch/die fillet radii, and the channel depth are the parameters studied. The analysis is conducted for a stainless steel SS304 with a thickness of 0.15 mm. The results show that the maximum value of thinning occurs always in the U-bend channel section, specifically in the fillet radius of the die closest to the axis of revolution. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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14 pages, 41796 KiB

Open AccessArticle

Dynamic Uniform Deformation for Electromagnetic Uniaxial Tension

by Xiaohui Cui, Zhiwu Zhang, Hailiang Yu, Yongqi Cheng and Xiaoting Xiao

Metals 2019, 9(4), 425; https://doi.org/10.3390/met9040425 - 09 Apr 2019

Cited by 4 | Viewed by 2597

Abstract

To compare with quasi-static uniaxial tensioning, researchers designed an electromagnetic uniaxial tension method using a runway coil. However, the requirements to obtain a uniformly deformed sample and the ways the stress changes on the sample using a runway coil have not been studied in the past. In this study, a three-dimensional (3D) sequential coupling method was developed to analyze the factors affecting on-sheet deformation inhomogeneity under electromagnetic uniaxial tension. Two main process parameters, comprising the die type and the relative position of the coil and sheet, were evaluated. Under the optimal parameters, the experiment and simulation both obtained uniformly deformed samples with different discharge conditions, and the simulation method had a high accuracy in modeling the deformation process. The stress state of the sample is approximately unidirectional tensile stress before 240 μs. After 240 μs, the three main stresses showed significant oscillations. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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36 pages, 18402 KiB

Open AccessArticle

Simulation of Sheet Metal Forming Processes Using a Fully Rheological-Damage Constitutive Model Coupling and a Specific 3D Remeshing Method

by Abel Cherouat, Houman Borouchaki and Jie Zhang

Metals 2018, 8(12), 991; https://doi.org/10.3390/met8120991 - 26 Nov 2018

Cited by 12 | Viewed by 4794

Abstract

Automatic process modeling has become an effective tool in reducing the lead-time and the cost for designing forming processes. The numerical modeling process is performed on a fully coupled damage constitutive equations and the advanced 3D adaptive remeshing procedure. Based on continuum damage mechanics, an isotropic damage model coupled with the Johnson–Cook flow law is proposed to satisfy the thermodynamic and damage requirements in metals. The Lemaitre damage potential was chosen to control the damage evolution process and the effective configuration. These fully coupled constitutive equations have been implemented into a Dynamic Explicit finite element code Abaqus using user subroutine. On the other hand, an adaptive remeshing scheme in three dimensions is established to constantly update the deformed mesh to enable tracking of the large plastic deformations. The quantitative effects of coupled ductile damage and adaptive remeshing on the sheet metal forming are studied, and qualitative comparison with some available experimental data are given. As illustrated in the presented examples this overall strategy ensures a robust and efficient remeshing scheme for finite element simulation of sheet metal-forming processes. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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14 pages, 4769 KiB

Open AccessArticle

Prediction and Experiment of Fracture Behavior in Hot Press Forming of a TA32 Titanium Alloy Rolled Sheet

by Ronglei Fan, Minghe Chen, Yong Wu and Lansheng Xie

Metals 2018, 8(12), 985; https://doi.org/10.3390/met8120985 - 23 Nov 2018

Cited by 12 | Viewed by 3172

Abstract

In aerospace and automotive industries, hot press forming (HPF) technology is widely used for rapid and precise deformation of the complex sheet metal component, where the fracture behavior has always been a focused problem. In this study, the hot tensile test and the Nakazima test were carried out, in order to establish the Misiolek constitutive equation and determine the forming limit strain points at an elevated temperature, respectively. The microstructure evolution during the tensile test was also investigated by optical microscope. In addition, the Marciniak–Kuczynski (M–K) model, considering the Mises, Hill48, and Logan–Hosford yield criteria, was utilized to calculate the theoretical forming limit curve (FLC). Furthermore, the fracture behavior of the TA32 alloy sheet during the HPF process was accurately predicted by inserting the predicted FLC into finite element simulation, and the qualified complex component was obtained by optimizing the shape of the sheet. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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14 pages, 5673 KiB

Open AccessArticle

Springback Prediction of Aluminum Alloy Sheet under Changing Loading Paths with Consideration of the Influence of Kinematic Hardening and Ductile Damage

by Zhenming Yue, Jiashuo Qi, Xiaodi Zhao, Houssem Badreddine, Jun Gao and Xingrong Chu

Metals 2018, 8(11), 950; https://doi.org/10.3390/met8110950 - 14 Nov 2018

Cited by 6 | Viewed by 4321

Abstract

Springback prediction of sheet metal forming is always an important issue in the industry, because it greatly affects the final shape of the product. The accuracy of simulation prediction depends on not only the forming condition but also the chosen material model, which determines the stress and strain redistributions in the formed parts. In this paper, a newly proposed elastoplastic constitutive model is used, in which the initial and induced anisotropies, combined nonlinear isotropic and kinematic hardenings, as well as isotropic ductile damage, are taken into account. The aluminum alloy sheet metal AA7055 was chosen as the studied material. In order to investigate springback under non-proportional strain paths, three-point bending tests were conducted with pre-strained specimens, and five different pre-straining states were considered. The comparisons between numerical and experimental results highlighted the hard effect of both kinematic hardening and ductile damage on the springback prediction, especially for a changed loading path case. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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15 pages, 4922 KiB

Open AccessFeature PaperArticle

Numerical Simulation of the Depth-Sensing Indentation Test with Knoop Indenter

by Maria I. Simões, Jorge M. Antunes, José V. Fernandes and Nataliya A. Sakharova

Metals 2018, 8(11), 885; https://doi.org/10.3390/met8110885 - 31 Oct 2018

Cited by 7 | Viewed by 2676

Abstract

Depth-sensing indentation (DSI) technique allows easy and reliable determination of two mechanical properties of materials: hardness and Young’s modulus. Most of the studies are focusing on the Vickers, Berkovich, and conical indenter geometries. In case of Knoop indenter, the existing experimental and numerical studies are scarce. The goal of the current study is to contribute for the understanding of the mechanical phenomena that occur in the material under Knoop indention, enhancing and facilitating the analysis of its results obtained in DSI tests. For this purpose, a finite element code, DD3IMP, was used to numerically simulate the Knoop indentation test. A finite element mesh was developed and optimized in order to attain accurate values of the mechanical properties. Also, a careful modeling of the Knoop indenter was performed to take into account the geometry and size of the imperfection (offset) of the indenter tip, as in real cases. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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25 pages, 1357 KiB

Open AccessFeature PaperArticle

Modeling of Forming Limit Bands for Strain-Based Failure-Analysis of Ultra-High-Strength Steels

by Hamid Reza Bayat, Sayantan Sarkar, Bharath Anantharamaiah, Francesco Italiano, Aleksandar Bach, Shashidharan Tharani, Stephan Wulfinghoff and Stefanie Reese

Metals 2018, 8(8), 631; https://doi.org/10.3390/met8080631 - 10 Aug 2018

Cited by 6 | Viewed by 4568

Abstract

Increased passenger safety and emission control are two of the main driving forces in the automotive industry for the development of light weight constructions. For increased strength to weight ratio, ultra-high-strength steels (UHSSs) are used in car body structures. Prediction of failure in such sheet metals is of high significance in the simulation of car crashes to avoid additional costs and fatalities. However, a disadvantage of this class of metals is a pronounced scatter in their material properties due to e.g., the manufacturing processes. In this work, a robust numerical model is developed in order to take the scatter into account in the prediction of the failure in manganese boron steel (22MnB5). To this end, the underlying material properties which determine the shapes of forming limit curves (FLCs) are obtained from experiments. A modified Marciniak–Kuczynski model is applied to determine the failure limits. By using a statistical approach, the material scatter is quantified in terms of two limiting hardening relations. Finally, the numerical solution obtained from simulations is verified experimentally. By generation of the so called forming limit bands (FLBs), the dispersion of limit strains is captured within the bounds of forming limits instead of a single FLC. In this way, the FLBs separate the whole region into safe, necking and failed zones. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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17 pages, 4094 KiB

Open AccessFeature PaperArticle

Modeling Bake Hardening Effects in Steel Sheets—Application to Dent Resistance

by Sandrine Thuillier, Shun-Lai Zang, Julien Troufflard, Pierre-Yves Manach and Anthony Jegat

Metals 2018, 8(8), 594; https://doi.org/10.3390/met8080594 - 30 Jul 2018

Cited by 10 | Viewed by 3819

Abstract

This study is dedicated to the experimental characterisation and phenomenological modeling of the bake hardening effect of a thin steel sheet, to predict the static dent resistance and perform an experimental validation on a bulged part. In a first step, rectangular samples are submitted to a thermo-mechanical loading to characterise the bake hardening magnitude in tension. A three-step procedure is considered, involving first a pre-strain in tension up to several values followed by unloading. Secondly, a heat treatment during a fixed time and a given temperature is performed, and finally, a reloading in tension in the same direction as the pre-strain is applied. Then, a specific device is developed to perform dent tests on a bulged specimen, to evaluate the influence of bake hardening on the dent resistance. A three-step procedure is also considered, with a pre-strain applied with a hydraulic bulge test followed by a heat treatment and then static dent test at the maximum dome height. An original phenomenological model is proposed to represent the yield stress increase after the heat treatment and the second reloading. Material parameters are identified from the tensile tests and are input data to a finite element model. The numerical prediction of the load evolution during the dent test is then compared with experimental data and shows an overall good correlation. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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11 pages, 4681 KiB

Open AccessArticle

Effect on Blank Holding Force on Blank Deformation at Direct and Indirect Hot Deep Drawings of Boron Steel Sheets

by Hyung Yoon Seo, Chul Kyu Jin and Chung Gil Kang

Metals 2018, 8(8), 574; https://doi.org/10.3390/met8080574 - 25 Jul 2018

Cited by 6 | Viewed by 5207

Abstract

This study involves performing direct and indirect hot press forming on ultra-high-strength steel (UHSS) boron steel sheets to determine formability. The indirect hot press process is performed as a cold deep drawing process, while the direct hot press process is performed as a hot deep drawing process. The initial blank temperature and the blank holding force are set as parameters to evaluate the performance of the direct and indirect deep drawing processes. The values of punch load and forming depth curve were obtained in the experiment. In addition, the hardness and microstructure of the boron steel sheets are examined to evaluate the mechanical properties of the material. The forming depth, maximum punch load, thickness, and thinning rate according to blank holding force were examined. The result shows that a larger blank holding force has a more significant effect on the variation of the thickness and thinning rate of the samples during the drawing process. Furthermore, the thinning rate of the deep drawing part in with and without fracture boundary was respectively examined. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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14 pages, 8080 KiB

Open AccessArticle

Predictive Simulation of Plastic Processing of Welded Stainless Steel Pipes

by Riccardo Rufini, Orlando Di Pietro and Andrea Di Schino

Metals 2018, 8(7), 519; https://doi.org/10.3390/met8070519 - 05 Jul 2018

Cited by 39 | Viewed by 4731

Abstract

Metal forming is the most used technique to manufacture complex geometry pieces in the most efficient way, and the technological progress related to the various application fields requires increasingly higher quality standards. In order to achieve such a requirement, people are forced to perform quality and compliance tests finalized to guarantee that these standards are met; this often implies a waste of material and economic resources. In the case of welded stainless steel pipes, several critical points affecting the general trend of subsequent machining need to be taken into account. In this framework, the aim of the paper is to study the effects of different process parameters and geometrical characteristics on various members of the stainless steel family during finite elements method (FEM) simulations. The analysis of the simulation outputs, such as stress, strain, and thickness, is reported through mappings, in order to evaluate their variation, caused by the variation of the simulation input parameters. The feasibility of the simulated process is evaluated through the use of forming limit diagrams (FLD). An experimental validation of the model is performed by comparison with real cases. Major parameters that mainly guide the outcome of the simulations are highlighted. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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15 pages, 7391 KiB

Open AccessArticle

Numerical Prediction of Forming Car Body Parts with Emphasis on Springback

by Peter Mulidrán, Marek Šiser, Ján Slota, Emil Spišák and Tomáš Sleziak

Metals 2018, 8(6), 435; https://doi.org/10.3390/met8060435 - 08 Jun 2018

Cited by 21 | Viewed by 4395

Abstract

Numerical simulation is an important tool which can be used for designing parts and production processes. Springback prediction, with the use of numerical simulation, is essential for the reduction of tool try-outs through the design of the forming tools with die compensation, therefore, increasing the dimensional accuracy of stamped parts and reducing manufacturing costs. In this work, numerical simulation was used for performing the springback analysis of car body stamping made of aluminium alloy AA6451-T4. The finite element analysis (FEM) based software PAM-STAMP 2G was used for performing the forming and springback simulations. These predictions were conducted with various combinations of material models to achieve accurate springback prediction results. Six types of yield functions (Barlat89, Barlat2000, Vegter-Lite, Hill90, Hill48 isotropic, and Hill48 orthotropic) were used in combination with the Voce hardening model. Springback analysis was conducted in three sections of the formed part; the numerical results were compared with the experimental values. It was found that the combinations of Barlat’s yield functions and the Voce hardening law were most accurate in terms of springback prediction. Additionally, it was found that the phenomena that were investigated, which are required for the determination of the kinematic hardening model, such as the change of Young’s modulus E, the transient behaviour, work-hardening stagnation, and permanent softening, were not observed in the aluminium alloy studied. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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4004 KiB

Open AccessArticle

Experimental and Numerical Studies of Sheet Metal Forming with Damage Using Gas Detonation Process

by Sandeep P. Patil, Kaushik G. Prajapati, Vahid Jenkouk, Herbert Olivier and Bernd Markert

Metals 2017, 7(12), 556; https://doi.org/10.3390/met7120556 - 10 Dec 2017

Cited by 18 | Viewed by 5501

Abstract

Gas detonation forming is a high-speed forming method, which has the potential to form complex geometries, including sharp angles and undercuts, in a very short process time. Despite many efforts being made to develop detonation forming, many important aspects remain unclear and have not been studied experimentally, nor numerically in detail, e.g., the ability to produce sharp corners, the effect of peak load on deformation and damage location and its propagation in the workpiece. In the present work, DC04 steel cups were formed using gas detonation forming, and finite element method (FEM) simulations of the cup forming process were performed. The simulations on 3D computational models were carried out with explicit dynamic analysis using the Johnson–Cook material model. The results obtained in the simulations were in good agreement with the experimental observations, e.g., deformed shape and thickness distribution. Moreover, the proposed computational model was capable of predicting the damage initiation and evolution correctly, which was mainly due to the high-pressure magnitude or an initial offset of the workpiece in the experiments. Full article

(This article belongs to the Special Issue Modelling and Simulation of Sheet Metal Forming Processes)

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