Abstract
Sheet metal forming is an inherent part of todays production industry. A major goal is to increase the forming limits of classical deep-drawing processes. One possibility to achieve that is to combine the conventional quasi-static (QS) forming process with electromagnetic high-speed (HS) post-forming. This work focuses on the finite element analysis of such combined forming processes to demonstrate the improvement which can be achieved. For this purpose, a cooperation of different institutions representing different work fields has been established. The material characterization is based on flow curves and forming limit curves for low and high strain rates obtained by novel testing devices. Further experimental investigations have been performed on the process chain of a cross shaped cup, referring to both purely quasi-static and quasi-static combined with electromagnetic forming. While efficient mathematical optimization algorithms support the new viscoplastic ductile damage modelling to find the optimum parameters based on the results of experimental material characterization, the full process chain is studied by means of an electro-magneto-mechanical finite element analysis. The constitutive equations of the material model are integrated in an explicit manner and implemented as a user material subroutine into the commercial finite element package LS-DYNA.
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Acknowledgments
This work is based on the results of PAK343 Methods for quasi-static-dynamic combined forming processes within the projects TP1 (O. Koray Demir, Christian Weddeling and A. Erman Tekkaya), TP2 (Marco Rozgic̀ and Marcus Stiemer), TP3 (Yalin Kiliclar, Stefan Wulfinghoff and Stefanie Reese) and TP4 (Marcus Engelhardt, Christian Klose and Hans Jürgen Maier). The authors would like to thank the German Science Foundation (DFG) for its financial support.
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Kiliclar, Y., Vladimirov, I.N., Wulfinghoff, S. et al. Finite element analysis of combined forming processes by means of rate dependent ductile damage modelling. Int J Mater Form 10, 73–84 (2017). https://doi.org/10.1007/s12289-015-1278-z
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DOI: https://doi.org/10.1007/s12289-015-1278-z