Advanced numerical framework to simulate Incremental Forming Processes

The framework of the present work supports the numerical analysis of the Single Point Incremental Forming (SPIF) process resorting to a numerical tool based on adaptive remeshing procedure based on the FEM. Mainly, this analysis concerns the computation time reduction from the implicit scheme and the adaptation of a solid-shell finite element type chosen, in particular the Reduced Enhanced Solid Shell (RESS). The main focus of its choice was given to the element formulation due to its distinct feature based on arbitrary number of integration points through the thickness direction. As well as the use of only one Enhanced Assumed Strain (EAS) mode. Additionally, the advantages include the use of full constitutive laws and automatic consideration of double-sided contact, once it contains eighth physical nodes.
Initially, a comprehensive literature review of the Incremental Sheet Forming (ISF) processes was performed. This review is focused on original contributions regarding recent developments, explanations for the increased formability and on the state of the art in finite elements simulations of SPIF. Following, a description of the numerical formulation behind the numerical tools used throughout this research is presented, summarizing non-linear mechanics topics related with finite element in-house code named LAGAMINE, the elements formulation and constitutive laws. The main purpose of the present work is given to the application of an adaptive remeshing method combined with a solid-shell finite element type in order to improve the computational efficiency using the implicit scheme. The adaptive remeshing strategy is based on the dynamic refinement of the mesh locally in the tool vicinity and following its motion. This request is needed due to the necessity of very refined meshes to simulate accurately the SPIF simulations. An initially mesh refinement solution requires huge computation time and coarse mesh leads to an inconsistent results due to contact issues. Doing so, the adaptive remeshing avoids the initially refinement and subsequently the CPU time can be reduced.
The numerical tests carried out are based on benchmark proposals and experiments purposely performed in University of Aveiro, Department of Mechanical engineering, resorting to an innovative prototype SPIF machine. As well, all simulations performed were validated resorting to experimental measurements in order to assess the level of accuracy between the numerical prediction and the experimental measurements. In general, the accuracy and computational efficiency of the results are achieved.