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Study on one-step simulation for the bending process of extruded profiles

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Abstract

Traditional one-step approaches are either based on the membrane element in which bending effects cannot be considered or based on the simplified shell element in which the initial blank is flat and the curvatures are kept unchanged in the one-step iterative computation. They are not suitable for the bending process of extruded profiles. In order to inspect the formability and possible forming defects in profile bending for preliminary designs quickly and to provide an efficient finite element computation for process analysis, a new one-step approach is presented. In this approach, instead of the traditional simplified shell element, the rotation-free basic shell triangular element is introduced to consider bending effects and make the new one-step approach suited to the simulation of profile bending. On the basis of the presented one-step approach, an in-house program named profile bending simulation-one step (PBS-ONESTEP) has been developed to simulate stretch bending of aluminum extrusions and three-point bending of stainless steel extrusions. The algorithm for initial guess solution of extruded profiles is described. Sliding constraint and the penalty method are adopted to treat contacts for the two numerical examples, respectively. The numerical results of PBS-ONESTEP simulation are compared with those of ABAQUS/EXPLICIT incremental analyses and experiments.

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Authors and Affiliations

  1. Department of Plasticity Technology, Shanghai Jiaotong University, Shanghai, 200030, China

    Lijun Fu, Xianghuai Dong & Peng Wang

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  1. Lijun Fu
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  2. Xianghuai Dong
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  3. Peng Wang
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Correspondence to Lijun Fu.

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Fu, L., Dong, X. & Wang, P. Study on one-step simulation for the bending process of extruded profiles. Int J Adv Manuf Technol 43, 1069–1080 (2009). https://doi.org/10.1007/s00170-008-1786-9

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  • DOI: https://doi.org/10.1007/s00170-008-1786-9

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