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Fast resolution of incremental forming processes by the Multi-Mesh method. Application to cogging

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Abstract

A Multi-Mesh Multi-Physics (MMMP) method is developed to reduce the very long computational time required for simulating incremental forming processes such as cogging or ring rolling. It consists in using several finite element meshes on the same domain to solve the different physics of the problem. A reference mesh is used to accurately store the results and history variables, while the different computational meshes are optimized to solve each physic of the problem. The MMMP algorithm consists in two main key-steps: the generation of the different unstructured meshes and the data transfer between the meshes. The accuracy of the method is supported by using meshes that are embedded by nodes. The method is applied to the simulation of the cogging metal forming process for which it shows as accurate and more than ten times faster than the standard method with a single mesh.

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Acknowledgments

This work was supported by the consortium « club forgeage libre » which gathers the following industries: ArcelorMittal, Cézus (Areva), Sfarsteel (Areva), Aubert & Duval and Manoir industries.

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Authors and Affiliations

  1. Ecole Centrale de Nantes, Laboratoire GEM, 1 Rue Noë, 44300, Nantes, France

    Mohamad Ramadan

  2. Mines ParisTech, CEMEF - Centre for Material Forming, 1 rue Claude Daunesse, 06904, Sophia Antipolis Cedex, France

    Lionel Fourment & Hugues Digonnet

Authors
  1. Mohamad Ramadan
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  2. Lionel Fourment
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  3. Hugues Digonnet
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Correspondence to Mohamad Ramadan.

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Ramadan, M., Fourment, L. & Digonnet, H. Fast resolution of incremental forming processes by the Multi-Mesh method. Application to cogging. Int J Mater Form 7, 207–219 (2014). https://doi.org/10.1007/s12289-012-1121-8

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  • DOI: https://doi.org/10.1007/s12289-012-1121-8

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