Modeling The Interaction Effects Between Tools And The Work Piece For Metal Forming Processes

In metal forming processes especially in cold forming, elastic deformation of the tools has a big impact on the final shape of the work‐piece. Computation of such processes considering the plastic effects of the work‐piece and elastic deformations of the tools at a time in a single FE model complicates to manage the convergence criteria. This situation is even aggravated if the contact situations (between working and support rolls) have to be considered in the simulation, which requires a very fine discretization of the contact zones of both the tool and work piece. This paper presents recently developed concept which meets the above mentioned demands very effectively. Within this concept, the computation of the elastic effects of the tools is separated from the process simulation (which considers elastic‐plastic effects of the work‐piece). Both simulations are coupled via automatic data interchange, which is bi‐directional, because both simulations influence each other. The advantages of this concept inc...