Lecture - 32 (MMF) Finite element method for Metal forming: The Concept by Prof. Santosh Kumar Department of Mechanical Engineering Institute of Technology, B.H.U. Varanasi 221005 e-mail: santosh.kumar.mec@itbhu.ac.inClassification for planned activities in metal forming L ANAYTICAL ‘METHODS 1, LIMIT ANALYSIS w NUMERICAL, METHODS 2. FORCE EQUILIBRIUM, 3. ETC. SCALED-DOWN MODEL MODELLING MATERIALS (wax LABORATORY)A Brief History of the FEM The label "finite element method" was first used by Clough (1960) in plane elasticity problems. But the ideas of FEM date back much further. The applied mathematician, the physicist and the engineer each developed the essential ideas of the FEM independently at different times and for different reasons. The applied mathematicians were concerned with boundary value problems of continuum mechanics: in particular, they wanted to find approximate upper and lower bounds for eigen values. The physicists were also interested in solving continuum problems, but they sought means to obtain piecewise approximate function to represent their continuous functions. Aerospace engineers were searching for a way to find the stiffness influence coefficients of shell-type complex structures. THAT IS HOW FEM EVOLVED !!The Finite Element Method (FEM) —A process simulation method Is a numerical analysis, technique for obtaining approximate solutions to a wide variety of engineering problems. It is popular in academic institution and in industry because of its diversity and flexibility as an analysis tool. A Finite Element Model of a problem gives a piecewise approximation to the governing equations. The basic premise of the FEM is that a solution region can be analytically approximated by replacing it with an assemblage of discrete elements, In fact, the term simulation is derived from the Latin word “simulare” what means “to pretend”. However, the technical meaning of simulation is the description and reproduction of physical and technical processes by use of mathematical and physical models. In comparison with practical tests the simulation often is cheaper and not so dangerous.Because of higher requirements on the quality of products and narrow tolerances of measures, optimising, planning and simulating of forming processes becomes more and more important. As the computational power has increased during the last years, numerical methods play an outstanding roll. The most important numerical method is the method of finite elements (FEM). Numerous finite element programmes have been developed which are able to solve linear, non linear, static, dynamic, elastic, plastic, elastic — plastic, steady state, transient, isotherm as well as non isotherm problems, during the last years. In this case we have to differ between ‘general purpose’ and ‘special purpose’ programs ES Santosh Kumar earn nd Commonicaton Techetogy(NMEICT) Department of Mechanical Engineering Ministryof Human Resource Development Institute of technology, Banaras Hindu University Gavermncntofiod ws g Varanasi 221005 (india) aToday many forming processes are carried out without a previous or accompanied finite clement analysis of course. However, if the material flow or the loads of the rolling devices have to be investigated exactly, the numerical simulation is a must, if one does not want to invest too much money and time in practical experiments. Furthermore practical experiments cause a loss of production of a rolling plant, for example. If the material flow and the stresses in the rolling pieces as well as the forming tools are well known, critical forming steps and deformations can be corrected and avoided. (e.g. in manufacturing: temperature distribution of tool) and fluid mechanics applications.FEM approach begins with the governing equations of the problem and proceeds without relying on a variational statement. Using this method. the FEM can be extended to problems where no functional is available and it i widely used in heat transfer From the problem to the model A given technical problem must be expressed by physical terms so that it can be formulated mathematically, what means modelling. The model should reflect the reality as exactly as possible. However, it should also be as simple as possible. Furthermore, the model must be described this way that it can be implemented in computers.Numerical problems like divisions by extremely low numbers or poor convergences of iterations, respectively, have to be mastered or to be avoided. Trial runs of the computational simulations and a subsequent check of the results by comparison with reality or physical experiments are a must. A special attention has to be directed to the boundary and initial conditions during modelling, because they have a decisive influence on the extent of the model as well as on its reliability. If the results do not coincide with reality or with the expectations close to reality, the model must be checked and possibly modified, whereby it will become bigger and more complicated.How the FEM works? A continuum is defined as a body of matter (solid, liquid or gas) or simply a region of space in which a particular phenomenon is occurring, In a continuum problem of any dimension, the field variable (whether it is pressure, temperature, displacement, stress or some other quantity) possesses infinitely many values because it is a function of each generic point in the body or solution space, Consequently, the problem is one with a finite number of unknowns. The FE discretization procedures reduce the problem to one of a finite number of unknowns, This is done by dividing ‘he solution region into elements and by expressing the unknown field variable in terms of assumed approximating functions within each element. The approximating functions (sometimes called interpolation functions) are defined in terms of the values of the field variables at specified points called nodes or nodal points.Nodes usually lie on the elements boundaries where adjacent elements are connected. In addition to boundary nodes, elements may also have a few interior nodes. The nodal values of the field variable and the interpolation functions for the elements completely define the behavior of the field variable within the elements. For the FE representation of a problem the nodal values of the field variable becomes the unknowns, Once these unknowns are found, the interpolation functions define the field variable throughout the assemblage of elements. Often interpolation functions are chosen so that the field variable or its derivatives are continuous across adjoining element boundaries. The important feature of the FEM is the ability to formulate problem for individual elements and putting them together represent the entire problem.In FEM basically there are three approaches to formulate the problem or the properties of the individual elements: 1. Direct approach: It uses direct stiffness method of structural analysis. It can be used for relatively simple problems. It requires the knowledge of matrix algebra in dealing with the FE equations and it is easiest to understand. 2. Variational approach: It relies on the calculus of variations and involves extreminizing a functional. For problems in solid mechanics (e.g. the plasticity problems in manufacturing) the functional turns out to be the potential energy, the complementary energy or some variant of these, such as the Reissner variational principle. The variational approach can be employed for both simple and sophisticated element shapes (ie.to a wide variety of engineering problems).3. Weighted residual approach: It is even more versatile approach to deriving element properties. This approach begins with the governing equations of the problem and proceeds without relying on a variational statement. Using this, the FEM can be extended to problems where no functional is available and it is widely used in heat transfer (e.g. in manufacturing, temperature distribution of tool etc.) and fluid mechanics applications.Steps involved in FEM solution 1. Discretize the continuum: The number and type of element in a given problem is also important and its selection requires engineering judgment and experience. 2. Select the interpolation Functions: The next step is to assign nodes to each element and then choose the interpolation function to represent the variation of the field variable over the element, The degree of the polynomial chosen depends on the number of nodes assigned to the clement, the nature and number of unknowns at each node certain continuity requirements imposed at the nodes and along the element boundaries. 3. Find the element properties: Once the elements and their interpolation functions have been selected, the properties of the individual elements (i.e. the matrix equations) can be determined by one of the three approaches ic. the direct approach, the variational approach or the weighted residuals approach.4. Assemble the element properties to obtain the system equations: one combines the matrix equations expressing the behavior of the elements and form the matrix equations expressing the behavior of the entire system. The basis for the assembly procedure starts from the fact that at a node, where elements are interconnected, the value of the field variable is the same for each element sharing that node. 5. Impose the boundary conditions; At this stage we impose known nodal values of the dependent variable or nodal loads and accordingly the system equations gets modified to get solution. 6. Solve the system equations: The assembly process gives a set of simultances equations that we solve. to obtain unknown nodal values of the problems. If the problem describes steady or equilibrium behaviour, then we must solve a set of linear or nonlinear algebraic equations. If the problem is unsteady, the nodal unknowns are a function of time, and we must solve a set of linear or nonlinear ordinary differential equations. 7. Make additional computations if desired (post processing): Solutions so obtained could be used to calculate other important parameters.The Finite Element Method Three steps: Pre — Solver - Post Forging Crash simulation MachiningFinite Elements in 2 Minutes Aim: Solve PDE (mechanics) External forces = internal stresses Stress o = o(2) Equation for displacement i Displacement can be any function Simple Answer Divide structure into Elements with simple deformation (linear, quadratic) Search for best solution Division: Mesh Mesh corners: NodesDerivation of the basic FEM equation Finite elements method: Method to discretize partial differential equations PDE of Mechanics: oe +f@ <0 anfinaie virtual displacement 5¥(%) (D’ALEMBERT) (52 70) 30-0 Integrate i (2 +70) dG) dV =0 Weak form of equation 60(X): Test function “tests”, if equation is fulfilled. %Derivation of the basic FEM equation Le -J@) 89) dV =0 Solve for i (real displacement): (8) = af €(8) = o( HO) Partial integration (chain rule): {/” fe" = [fg] — f.°f'g ay poe area adv) fi@s@es+ [ Fosn@av— [ ow ar aV=0 #(@) : surface traction eee : Virtual strain (deriv. of virtual displacement) Ix f 1@dv@ ds+ if F@HSv@ av = ft o(oedVv Basic Finite Element EquationYou can now test yourself and prepare to evaluate for the understanding of this Lecture by answering questions Thank you all for your patience Please do not forget to give your valuable feedback /suggestion to improve