Damage Prediction in Metal Forming Process Modeling and Optimization: Simplified Approaches

Some simplified numerical methods for damage predictions in metal forming process modeling and optimization are presented in this chapter. The incremental approaches including advanced damage models lead to accurate results, but the simulations are tedious and time-consuming. An efficient solving algorithm called inverse approach (IA) allows the fast modeling of forming processes in only one step between the known final part and the initial blank, avoiding the contact treatment and the incremental plastic integration. To improve the stress estimation in the IA, the so-called pseudo-inverse approach (PIA) has been developed. Some intermediate configurations are geometrically created and corrected by a free surface method to consider the deformation path, and the plastic integration based on the flow theory is carried out incrementally to consider the loading history. A simplified 3D strain-based damage model is coupled with the plasticity and implemented into a direct scalar integration algorithm of plasticity (without local iterations), which makes the plastic integration very fast and robust even for very large strain increments. These simplified approaches lead to very fast and useful numerical tools in the preliminary design and optimization.

[1]  Hakim Naceur.  Optimisation de forme de structures minces en grandes transformations , 2010 .

[2]  J. M. Detraux,et al.  Finite element procedures for strain estimations of sheet metal forming parts , 1990 .

[3]  Boussad Abbès,et al.  Simulation of axi-symmetrical cold forging process by efficient pseudo inverse approach and direct algorithm of plasticity , 2012 .

[4]  Naksoo Kim,et al.  Preform design in H-shaped cross sectional axisymmetric forging by the finite element method , 1990 .

[5]  Hakim Naceur,et al.  An efficient DKT rotation free shell element for springback simulation in sheet metal forming , 2002 .

[6]  Paul R. Dawson,et al.  Damage Evolution Modeling in Bulk Forming Processes , 1987 .

[7]  Olaf Schenk,et al.  Optimal design of metal forming die surfaces with evolution strategies , 2004 .

[8]  Eugenio Oñate,et al.  Plastic and viscoplastic flow of void‐containing metals. Applications to axisymmetric sheet forming problems , 1988 .

[9]  Hakim Naceur,et al.  A fast algorithm for strain prediction in tube hydroforming based on one-step inverse approach , 2011 .

[10]  Hakim Naceur,et al.  New Enhancements in the Inverse Approach for the Fast Modeling of Autobody Stamping Process , 2002, Int. J. Comput. Eng. Sci..

[11]  B. Nayroles,et al.  Generalizing the finite element method: Diffuse approximation and diffuse elements , 1992 .

[12]  Michael T. M. Emmerich,et al.  Single- and multiobjective evolutionary optimization assisted by Gaussian random field metamodels , 2006, IEEE Transactions on Evolutionary Computation.

[13]  Lionel Fourment,et al.  Shape optimization of axisymmetric preform tools in forging using a direct differentiation method , 2001 .

[14]  G. Rousselier,et al.  Ductile fracture models and their potential in local approach of fracture , 1987 .

[15]  Karl Debray,et al.  Inverse vs Incremental Numerical Approaches for Ductile Damage Prediction in Sheet Metal Forming , 2004 .

[16]  P. Villon,et al.  Moving least squares response surface approximation: Formulation and metal forming applications , 2005 .

[17]  Y. Guo,et al.  Response surface methodology for design of sheet forming parameters to control springback effects , 2006 .

[18]  Boussad Abbès,et al.  Two Efficient Algorithms of Plastic Integration for Sheet Forming Modeling , 2007 .

[19]  Pascal Lafon,et al.  Methodology of the shape optimization of forging dies , 2010 .

[20]  Larsgunnar Nilsson,et al.  Tube hydroforming of aluminium extrusions using a conical die and extensive feeding , 2008 .

[21]  Nikolaos Aravas,et al.  The analysis of void growth that leads to central bursts during extrusion , 1986 .

[22]  F. Barlat,et al.  Plane stress yield function for aluminum alloy sheets—part 1: theory , 2003 .

[23]  Tomas Jansson,et al.  Optimization of Draw-In for an Automotive Sheet Metal Part An evaluation using surrogate models and response surfaces , 2005 .

[24]  Karl Debray,et al.  Design and Optimization of Addendum Surfaces in Sheet Metal Forming Process , 2007 .

[25]  J. C. Simo,et al.  A return mapping algorithm for plane stress elastoplasticity , 1986 .

[26]  Hakim Naceur,et al.  Optimization of drawbead restraining forces and drawbead design in sheet metal forming process , 2001 .

[27]  N. Metropolis,et al.  Equation of State Calculations by Fast Computing Machines , 1953, Resonance.

[28]  A. L. Gurson,et al.  Porous Rigid Plastic Materials Containing Rigid Inclusions; Yield Function, Plastic Potential and Void Nucleation , 1976 .

[29]  Carl Labergère,et al.  Optimization of Forging Preforms by Using Pseudo Inverse Approach , 2012 .

[30]  C. D. Gelatt,et al.  Optimization by Simulated Annealing , 1983, Science.

[31]  Ramana V. Grandhi,et al.  Studies on optimization of metal forming processes using sensitivity analysis methods , 2004 .

[32]  J. Oudin,et al.  An Improved Finite Element Method for the Analysis of Damage and Ductile Fracture in Cold Forming Processes , 1985 .

[33]  Boussad Abbès,et al.  An Efficient Axi-symmetric Element Based on Inverse Approach for Cold Forging Modeling , 2010 .

[34]  Wang June,et al.  An anisotropic damage criterion for deformation instability and its application to forming limit analysis of metal plates , 1985 .

[35]  K. Deb.  An Efficient Constraint Handling Method for Genetic Algorithms , 2000 .

[36]  J. Chaboche,et al.  Mechanics of Solid Materials , 1990 .

[37]  M. D. McKay,et al.  A comparison of three methods for selecting values of input variables in the analysis of output from a computer code , 2000 .

[38]  Raghavan Srinivasan,et al.  Optimum Design of Forging Die Shapes Using Nonlinear Finite Element Analysis , 1993 .

[39]  C. Labergere,et al.  Recent Advances in Process Optimization and Control for the Design of Sheet and Tube Hydroforming Processes , 2005 .

[40]  Kichan Son,et al.  Optimum blank shape design by sensitivity analysis , 2000 .

[41]  R. E. Dick,et al.  Plane stress yield functions for aluminum alloy sheets , 2002 .

[42]  Khemais Saanouni,et al.  Damage Modeling in Metal Forming Processes , 2000 .

[43]  Khemais Saanouni,et al.  Damage Mechanics in Metal Forming: Saanouni/Damage Mechanics in Metal Forming , 2012 .

[44]  Hoon Huh,et al.  Blank Design and Strain Estimates for Sheet Metal Forming Processes by a Finite Element Inverse Approach with Initial Guess of Linear Deformation , 1998 .

[45]  P. Lestriez,et al.  Numerical Simulation of Ductile Damage in Metal Forming Processes. A Simple Predictive Model. 1. Theoretical and Numerical Aspects , 2002 .

[46]  Serge Cescotto,et al.  A fully coupled elastoplastic damage modeling and fracture criteria in metalforming processes , 1992 .

[47]  Douglas C. Montgomery,et al.  Response Surface Methodology: Process and Product Optimization Using Designed Experiments , 1995 .

[48]  Peter Hartley,et al.  The Prediction of Ductile Fracture Initiation in Metalforming Using a Finite-Element Method and Various Fracture Criteria , 1989 .

[49]  G. Dhatt,et al.  Modélisation des structures par éléments finis , 1990 .

[50]  Ramana V. Grandhi,et al.  PREFORM DIE SHAPE DESIGN IN METAL FORMING USING AN OPTIMIZATION METHOD , 1997 .

[51]  J. Chaboche.  Continuum Damage Mechanics: Part I—General Concepts , 1988 .

[52]  Jean-Claude Gelin,et al.  Optimization of metal forming process parameters with damage minimization , 1998 .

[53]  Thomas J. Santner,et al.  The Design and Analysis of Computer Experiments , 2003, Springer Series in Statistics.

[54]  Hakim Naceur,et al.  An Heuristic Optimization Algorithm for the blank shape design of high precision metallic parts obtained by a particular stamping process , 2008 .

[55]  Jean-Loup Chenot,et al.  OPTIMAL DESIGN FOR NON‐STEADY‐STATE METAL FORMING PROCESSES—I. SHAPE OPTIMIZATION METHOD , 1996 .

[56]  K. Debray,et al.  An efficient pseudo-inverse approach for damage modeling in the sheet forming process , 2004 .