[en] 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.
Disciplines :
Materials science & engineering
Author, co-author :
Sena, José; University of Aveiro, Aveiro, Portugal > Department of Mechanical Engineering,
Lequesne, Cedric; SAMTECH SA, Liège, Belgium
Duchene, Laurent ; Université de Liège > Département ArGEnCo > Analyse multi-échelles des matériaux et struct. du gén. civ.
Habraken, Anne ; Université de Liège > Département ArGEnCo > Département ArGEnCo
Valente, Robertt; University of Aveiro, > Department of Mechanical Engineering
Alves de Sousa, ricardo
Language :
English
Title :
Single point incremental forming simulation with adaptive remeshing technique using solid-shell elements
Publication date :
June 2016
Journal title :
Engineering Computations
ISSN :
0264-4401
eISSN :
1758-7077
Publisher :
Emerald, Bingley, United Kingdom
Volume :
33
Issue :
5
Pages :
1388-1421
Peer reviewed :
Peer Reviewed verified by ORBi
Tags :
CÉCI : Consortium des Équipements de Calcul Intensif
ABAQUS (2005), Theory Manual, Version 6.5, Hibbit, Karlsson & Sorensen Inc., San Francisco, CA.
Aerens, R., Eyckens, P., Bael, A. and Duflou, J. R. (2009), "Force prediction for single point incremental forming deduced from experimental and FEM observations", The International Journal of Advanced Manufacturing Technology, Vol. 46 Nos 9-12, pp. 969-982.
Allwood, J. M., Braun, D. and Music, O. (2010), "The effect of partially cut-out blanks on geometric accuracy in incremental sheet forming", Journal of Materials Processing Technology, Vol. 210 No. 11, pp. 1501-1510.
Alves De Sousa, R. J., Jorge, R. M. N., Valente, R. A. F. and César De Sá, J. M. A. C. (2003), "A new volumetric and shear locking-free 3D enhanced strain element", Engineering Computations, Emerald, Vol. 20 No. 7, pp. 896-925.
Alves De Sousa, R. J., Yoon, J., Cardoso, R., Fontes Valente, R. and Gracio, J. (2007), "On the use of a reduced enhanced solid-shell (RESS) element for sheet forming simulations", International Journal of Plasticity, Vol. 23 No. 3, pp. 490-515.
Alves De Sousa, R. J., Cardoso, R. P. R., Fontes Valente, R. A., Yoon, J.-W., Gracio, J. J. and Natal Jorge, R. M. (2005), "A new one-point quadrature enhanced assumed strain (EAS) solid-shell element with multiple integration points along thickness: part I - geometrically linear applications", International Journal for Numerical Methods in Engineering, Vol. 62 No. 7, pp. 952-977.
Alves De Sousa, R. J., Cardoso, R. P. R., Fontes Valente, R. A., Yoon, J.-W., Grácio, J. J. and Natal Jorge, R. M. (2006), "A new one-point quadrature enhanced assumed strain (EAS) solidshell element with multiple integration points along thickness - part II: nonlinear applications", International Journal for Numerical Methods in Engineering, Vol. 67 No. 2, pp. 160-188.
Ambrogio, G, Filice, L, Guerriero, F., Guido, R. and Umbrello, D. (2010), "Prediction of incremental sheet forming process performance by using a neural network approach", The International Journal of Advanced Manufacturing Technology, Vol. 54 Nos 9-12, pp. 921-930.
Arfa, H., Bahloul, R. and BelHadjSalah, H. (2012), "Finite element modelling and experimental investigation of single point incremental forming process of aluminum sheets: influence of process parameters on punch force monitoring and on mechanical and geometrical quality of parts", International Journal of Material Forming, Vol. 6 No. 4, pp. 483-510.
Bambach, M. (2014), "Fast simulation of asymmetric incremental sheet metal forming by adaptive remeshing and subcycling", International Journal of Material Forming, Vol. 847, pp. 844-847.
Bambach, M. and Hirt, G. (2007), "Error analysis in explicit finite element analysis of incremental sheet forming", AIP Conference Proceedings, Vol. 908, pp. 859-864.
Behera, A. K., Lauwers, B. and Duflou, J. R. (2014), "Tool path generation framework for accurate manufacture of complex 3D sheet metal parts using single point incremental forming", Computers in Industry, Vol. 65 No. 4, pp. 563-584.
Bouffioux, C, Eyckens, P., Henrard, C, Aerens, R., Bael, A., Van, Sol, H., Duflou, J. R. and Habraken, A. M. (2008), "Identification of material parameters to predict single point incremental forming forces", International Journal of Material Forming, Vol. 1 No. S1, pp. 1147-1150.
Bouffioux, C, Pouteau, P., Duchêne, L., Vanhove, H., Duflou, J. R. and Habraken, A. M. (2010), "Material data identification to model the single point incremental forming process", International Journal of Material Forming, Vol. 3 No. S1, pp. 979-982.
Cerro, I., Maidagan, E., Arana, J., Rivero, A. and Rodríguez, P. P. (2006), "Theoretical and experimental analysis of the dieless incremental sheet forming process", Journal of Materials Processing Technology, Vol. 177 Nos 1-3, pp. 404-408.
Cescotto, S. and Grober, H. (1985), "Calibration and application of an elastic viscoplastic constitutive equation for steels in hot-rolling conditions", Engineering Computations, Vol. 2 No. 2, pp. 101-106.
Driessen, B. (2002), "A direct stiffness-modification approach to attaining linear consistency between incompatible finite element meshes", in Constanda, C, Schiavone, P. and Mioduchowski, A. (Eds), Integral Methods in Science and Engineering, Springer-Verlag, doi: 10.1007/978-1-4612-0111-3-12.
Duflou, J. R., Vanhove, H., Verbert, J., Gu, J., Vasilakos, I. and Eyckens, P. (2010), "Twist revisited: twist phenomena in single point incremental forming", CIRP Annals - Manufacturing Technology, Vol. 59 No. 1, pp. 307-310.
Durante, M., Formisano, A., Langella, A. and Capece Minutolo, F. M. (2009), "The influence of tool rotation on an incremental forming process", Journal of Materials Processing Technology, Vol. 209 No. 9, pp. 4621-4626.
Emmens, W. C., Sebastiani, G. and Van Den Boogaard, A. H. (2010), "Technology the technology of incremental sheet forming - a brief review of the history", Journal of Materials Processing Technology, Vol. 210 No. 8, pp. 981-997.
Eyckens, P., Dellero Moreau, J., Duflou, J. R., Bael, A. and Houtte, P. (2009), "MK modelling of sheet formability in the incremental sheet forming process, taking into account through-thickness shear", International Journal of Material Forming, Vol. 2 No. S1, pp. 379-382.
Giraud-Moreau, L., Cherouat, A., Zhang, J. and Borouchaki, H. (2013), "Comparison between an advanced numerical simulations of sheet incremental forming using adaptive remeshing and experimental results", Key Enginneering Materials, Vols-554-557, pp. 1375-1381.
Guzmán, C. F., Gu, J., Duflou, J., Vanhove, H., Flores, P. and Habraken, AM. (2012), "Study of the geometrical inaccuracy on a SPIF two-slope pyramid by finite element simulations", International Journal of Solids and Structures, Vol. 49 No. 25, pp. 3594-3604.
Habraken, A. M. (1989), Contribution to the Modelling of Metal Forming By Finite Element Model, Université de Liège, Liege.
Habraken, A. M. and Cescotto, S. (1998), "Contact between deformable solids: the fully coupled approach", Mathematical and Computer Modelling, Vol. 28 Nos 4-8, pp. 153-169.
Hadoush, A. and Boogaard, A. H. (2009), "Substructuring in the implicit simulation of single point incremental sheet forming", International Journal of Material Forming, Vol. 2 No. 3, pp. 181-189.
Hadoush, A. and Van Den Boogaard, A. H. (2008), "Time reduction in implicit single point incremental sheet forming simulation by refinement-derefinement", International Journal of Material Forming, Vol. 1 No. S1, pp. 1167-1170.
Hadoush, A. M. H. (2010), Efficient Simulation and Process Mechanics of Incremental Sheet Forming, University of Twente, Twente.
Henrard, C. (2008), Numerical Simulations of the Single Point Incremental Forming Process, University of Liège, Liege.
Henrard, C., Bouffioux, C., Eyckens, P., Sol, H., Duflou, J. R., Van Houtte, P., Van Bael, A. and Habraken, A. M. (2010), "Forming forces in single point incremental forming: prediction by finite element simulations, validation and sensitivity", Computational Mechanics, Vol. 47 No. 5, pp. 573-590.
Jeswiet, J., Micari, F., Hirt, G., Bramley, A., Duflou, J. and Allwood, J. (2005), "Asymmetric single point incremental forming of sheet metal", CIRP Annals - Manufacturing Technology, Vol. 54 No. 2, pp. 88-114.
Jetteur, P. and Cescotto, S. (1991), "A mixed finite element for the analysis of large inelastic strains", International Journal for Numerical Methods in Engineering, Vol. 31 No. 2, pp. 229-239.
Kim, Y. and Park, J. (2002), "Effect of process parameters on formability in incremental forming of sheet metal", Journal of Materials Processing Technology, Vols-130-131, pp. 42-46.
Kopac, J. and Kampus, Z. (2005), "Incremental sheet metal forming on CNC milling machine-tool", Journal of Materials Processing Technology, Vols-162-163, pp. 622-628.
Lequesne, C., Henrard, C., Bouffioux, C., Duflou, J. R. and Habraken, A. M. (2008), "Adaptive remeshing for incremental forming simulation", Numisheet 2008, Vol. 32, Interlaken, pp. 4-8.
Leszak, E. (1967), "Apparatus and process for incremental dieless forming", Patent No. US3342051A1.
Li, K. (1995), Contribution to the Finite Element Simulation of Three-Dimensional Sheet Metal Forming, Université de Liège, Liege.
Martins, P. A. F., Kwiatkowski, L., Franzen, V., Tekkaya, A. E. and Kleiner, M. (2009), "Single point incremental forming of polymers", CIRP Annals - Manufacturing Technology, Vol. 58 No. 1, pp. 229-232.
Park, J.-J. and Kim, Y.-H. (2003), "Fundamental studies on the incremental sheet metal forming technique", Journal of Materials Processing Technology, Vol. 140 Nos 1-3, pp. 447-453.
Sena, J. I. V., Sousa, R. J. A., De and Valente, R. A. F. (2011), "On the use of EAS solid-shell formulations in the numerical simulation of incremental forming processes", Engineering Computations, Vol. 28 No. 3, pp. 287-313.
Sena, J. I. V., Guzman, C. F., Duchene, L., Habraken, A. M., Valente, R. A. F. and De Sousa, R. J. (2013), "Numerical simulation of a conical shape made by single point incremental", AIP Conference Proceedings, Numisheet Conference, Melbourne, 6-10 January, Vol. 1567, No. 1.
Simo, J. C. and Rifai, M. S. (1990), "A class of mixed assumed strain methods and the method of incompatible modes", International Journal for Numerical Methods in Engineering, Vol. 29 No. 8, pp. 1595-1638.
Suresh, K. and Regalla, S. P. (2014), "Effect of mesh parameters in finite element simulation of single point incremental sheet forming process", Procedia Materials Science, Vol. 6, pp. 376-382.
Yamashita, M., Gotoh, M. and Atsumi, S.-Y. (2008), "Numerical simulation of incremental forming of sheet metal", Journal of Materials Processing Technology, Vol. 199 Nos 1-3, pp. 163-172.
Yoon, J. W., Rolfe, B., Beynon, J. H. and Hodgson, P. (2013), NUMISHEET 2014: The 9th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes: Part A Benchmark Problems and Results and Part B General Papers, Numisheet Conference, Melbourne, 6-10 January, Vol. 1567.
