ACTA METALLURGICA SINICA (ENGLISH LETTERS)

Vol. 17 No. 3 pp 299-302 June 2004

STUDY ON THE FINITE ELEMENT NUMERICAL SIMULATION OF

SHEET METAL FORMING
J.L. Song1,2) , D.J. Hu1) , Z.L. Chang2) , T.Y. Li2) and Z.B. Jiang2)
1) School of Mechanical Engineering, Shanghai Jiaotong University, Shanghai 200030, China
2) Department of Materials Engineering, Taiyuan Heavy Machinery Institute, Taiyuan 030024, China
Manuscript received 11 October 2003

Based on the Finite Element Theory of Rigid Plastic, relevant problems during plas-
tic simulation on sheet metal forming were technologically studied and simplified; a
simplified model of the blank holder during the drawing process was established and
the effects of related parameters on the forming processes were also studied. At the
same time, a finite-element numerical simulation program SPID was developed. The
distribution of strain and relationship of stress-stroke simulated were compared with
experimented, the results are well coincided with each other. It is verified that the
analytical program is reliable.
KEY WORDS sheet metal forming, finite-element, numerical simulation

1. Introduction

With the development of the automobile and aeronautical industries, the forming preci-
sion of sheet and shell parts is enhanced greatly. However, because sheet metal forming is a
complex non-linear coupling process, geometry and boundary conditions, proper solution is
difficult to obtain with conventional methods. Through the FEM numerical simulation, the
forming defects can be forecasted and a scientific basis can be provided to process and die
designers, the forming quality can be improved and the design period can be shortened[1,2] .
A FEM numerical simulation program SPID[3] was developed, it can be used to analyze
the metal flow, calculate distributions of stress and strain of axial symmetric stamping
processes.

2. Technological Study of Relevant Problems in the Program

2.1 Frictional conditions
The normal press on the nodes was calculated according to the coulomb’s frictional
formulation. And it was assumed to be the normal force of the last iterative step.

2 ∆µti
Fs = −µP tanh( ) (1)
π α
The rigidity matrix is as follows

∂Fs 2 α
= − = µP · 2 (2)
µti π α + ∆µ2ti
Where Fs is normal press on nodes; µ is frictional coefficient, µ >0; P is normal stress
of the contacting face; ∆µti is relative slide speed of node i on the sheet-die interface; α is
minute positive number.
· 300 ·

2.2 Establishment of the initial velocity field

The stability of the velocity field is very important during the rigid plastic FEM so-
lution, especially during the beginning of the drawing, where the local stress and strain
changed rapidly. Initial velocity field has been established on the basis of the assumption
of the linear velocity ratio between equivalent stress and strain. The program can be re-
freshed automatically with direct iteration on the conditions of worse iteration. The linear
equations of the nodes velocity are as follows

s~v = ~r (3)
Where s is total rigidity matrix of the system; ~v is velocity vector on nodes; ~r is
force vector. Newton-Rophson method is adopted, the modification formula of the velocity
iteration is

~vn = ~vn−1 + β∆~vn (4)

Where ~vn is velocity field; n is number of iteration; ~vn−1 is approximate solution of
step n−1; ∆~vn is modification of step n; β is deceleration factor, 0<β ≤ 1.

2.3 Analysis of the drawing process at the beginning stage

At the beginning of the drawing, i.e. the deforming stage before the flange sheet drawn
into the die, a hanging region will be formed between the fillet of the punch and the
bottom, the fillet of the die and the end surface. The local reduction of thickness formed
by expansion result to a liability of cracking of the above regions[4] . The higher the strength
of the material, the shorter the transition stage will be.

2.4 Simplified model of the blank holder

The outer region of the flange is assumed to be under the force of the blank holder,
and the blanking force is uniform. The precision of the simplified model is perfectly well
comparing with the experiments. The frictional force on nodes can be determined with

2µPbh
Fs = (5)
Nb
Where Pbh is blanking force; Nb is total number of outer flange region; µ is frictional
coefficient.

3. Results and Discussion

In the experiment, related parameters in drawing and hole flanging process were tested
directly with a rigid blank holder and general structural die.
3.1 Strain along the thickness of cylindrical drawings
Parameters used (material: 08F): initial diameter Db =70mm; radius of punch and die:
rp =5.0mm, rd =5.0mm; frictional coefficient: µp =0.30, µd =0.05.
It can be seen from Fig.1 that at the beginning of the drawing, there has been a local
thickness reduction at the radius of the punch, the results simulated is well coincided with
the experiments.