Finite Element Simulation Of Metal Forming Process And Experimental Research

Finite element analysis has lately emerged as a critical technology to improve design ability of metal die, which is of great significance for shortening design periods, decreasing the number of testing punch, cutting down product's cost. In this paper, the state and development of simulation of metal sheet press forming processes are summarized, and some key problems which are not yet solved well currently with finite element method in practical applications are provided.The change of microstructure and the stress-strain in material forming processes are analyzed theoretically. The process of simulating schemes is introduced, and the selected dynamic explicit algorithm, explicit shell element, contact model and material model are explained in detail.The familiar forming defects are analyzed theoretically, while simulation analysis of some representative examples, including wrinkle simulation, crack simulation and springback simulation are carried out with finite element method. Some characteristics and rule of defects forming are presented, and the strain criterion and criterion of the rate of thickness' reduction are discussed in detail. Based on the finite element analysis, the corresponding methods are derived to avoid forming defects and repair dies.According to the forming defect analysis, some parameters of traditional forming process are optimized with finite element analysis, and some typical forming processes are simulated. The corresponding methods are provided for selection of blank material, optimization of blank shape, determination of binder force and forming force and parameters of draw bead's situation and shape optimization of progressive draw forming process with finite element analysis, and which are verified with simulation.Finally, a practical problem of die design is resolved with the derived methods based on the finite element simulation analysis, which are also verified with experiments, the results show that designing period is shortened, the cost of pre-production testing is cut down and the surface's quality of workpiece is improved in course of the die and press process design.