Damage Effect in Metal Forming Processes using Adaptive Remeshing

摘要

Virtual simulation has become an effective tool in reducing the lead-time and the cost. During metal forming, macroscopic cracks (ductile damage) often occur due to the large thermo-elasto(visco) plastic flow localisation. An intrinsic difficulty in metal forming process is when damage is taken into account an accurate remeshing procedure is needed in order to refine the mesh size inside the fully damaged zones which define the macroscopic crack. This leads to removing the fully damaged elements defining new free boundaries. Also, in metal forming, the mesh size should be adapted with respect to the curvature of complex tools in order to optimize the contact boundaries. These problems can be resolved if an adaptive remeshing scheme is incorporated automatically in the FE analysis. This paper presents a new iterative resolution scheme which aims to improve virtually any metal forming processes with respect to the damage effect. Numerical results are given to show the pertinence of the proposed resolution scheme.