Modelling of Metal Forming Processes: Proceedings of the Euromech 233 Colloquium, Sophia Antipolis, France, August 29–31, 1988

342 Pages·1988·16.729 MB·English

by  P. Mazilu, A. Skiadas (auth.), J. L. Chenot, E. Oñate (eds.)

MODELLING OF METAL FORMING PROCESSES
OfR elated Interest:
J. Caldwell & R. Bradley (eds.) Industrial Vibration Modelling, 1987,
ISBN 90--247-3423-1
O. D. D. Soares & Perez-Amor (eds.) Applied Laser Tooling, 1987,
ISBN 90--247-3486-x
R. J. Moreau (ed.) Measurement and Control in Liquid Metal Processing, 1987,
ISBN 90--247-3510--6
T. J. Smith (ed.) Modelling the Flow and Solidification of Metals, 1987,
ISBN 90--247-3526-2
G. N. Pande & J. Middleton (eds.) Numerical Techniques for Engineering Analysis
and Design,NUMETA 87, Volume 1, 1987,ISBN90--247-3564-5
G. N. Pande & J. Middleton (eds.) Transient/Dynamical Analysis and Constitutive
Laws for Engineering Materials, NUMETA 87, Volume 2, 1987,
ISBN 90--247-3565-3
Modelling of
Metal Forming Processes
Proceedings of the Euromech 233 Colloquium, Sophia Antipolis,
France, August 29-31, 1988
edited by
J.L. CHENOT
Centre de Mise en Forme des Materiaux,
Ecole Nationale Superieure des Mines de Paris,
Sophia Antipolis, Valbonne, France
and
E. ONATE
Escuela Tecnica Superior
de lngenieros de Caminos y Puertos,
Barcelona, Spain
KLUWER ACADEMIC PUBLISHERS
DORDRECHT / BOSTON / LONDON
Library of Congress Cataloging in Publication Data
EurCl1leCh ColloquiWII (233 : 1988 : Sophia Antipolis,
France)
Modelling of metal fonming processes.
1. Hctal-work--Computer sinulation--Congresses.
2. Finite element mcthod--Congresses. 1. Chenot,
J. L. 11. onate, E. III. Title.
ts213.EQ7 1988 671.3 88-13242
ISBN·13: 978·94·010·7131-4 e·ISBN-13: 978·94·009·1411·7
001: 10.1007/978-94-009-1411-7
Published by Kluwer Academic Publishers,
P.O. Box 17. 3300AA Dordrecht, 1be Netherlands.
Kluwer Academic Publishers incorporates
the publishing programmes of
D. Reidel. Martinus Nijhoff, Dr W. Junk andMTP Press.
Sold and distributed in the U.S.A. and Canada
by Kluwer Academic Publishers,
101 Philip Drive, Norwell, MA 02061 , U.S.A.
In all other countries. sold and distributed
by Kluwer Academic Publishers Group,
P.O. Box 322, 3300 AH Dordrecht, The Netherlands.
All Rights Reserved
© 1988 by Kluwer Academic Publishers
Softcover reprint of the hardcover 1st edition 1988
No part of the material protected by this copyright ootice may be reproduced or
utilized in any form or by any means, electronic or mechanical
including photocopying, recording or by any information storage and
retrieval system. without wrinen permission from the copyright owner
PREFACE
The physical modelling of metal forming processes has been widely used
both in University and in Industry for many years.
Relatively simple numerical models, such as the Slab Method and the
Upper Bound Method, were first used and many such models are implemented in
the industry for practical design or regulation of forming processes. These
models are also under investigation in the University, mainly for treat
ments which require low cost calculations or very fast answers for on-line
integration.
More recently, sophisticated numerical methods have been used for the
simulation of metal flow during forming operations. Since the early works
in 1973 and 1974, mainly in U.K. and U.S.A., the applications of the finite
element method to metal processing have been developed in many laboratories
all over the world. Now the numerical approach seems to be widely re
cognized as a powerful tool for comprehension oriented studies, for predic
ting the main technological parameters, and for the design and the optlmi
zation of new forming sequences. There is also a very recent trend for the
introduction of physical laws in the thermo-mechanical models, in order to
predict the local evolution of internal variable representing the micro
structure of the metal.
To day more and more practicians of the Industry are asking for compu
ter models for design of their forming processes. This volume represents an
effort to assess the present state of the art, in the development of compu
ter codes, in the validation of the models by comparison with experimental
data, and to stimulate exchanges between material scientists and engineers
from industry.
This volume contains contributions to :
- the analysis of the constitutive equations of material, the
friction law, the prediction of defects, and the physical modelling,
- the new developments in formulation of the finite element
method for metal flow including error estimation,
- application of real forming operations cold and hot rolling,
forging, drawing, sheet forming and casting.
It is a pleasure for the editors to thank Pr J. who sugges
SALEN~ON,
ted the idea of the colloquium, and assisted us for its organization. They
finally wish to congratulate the authors for their excellent work, and
thank them for making this conference successful.
The editors
J.L. CHENOT
E. O~ATE
v
Scientific Committee
J.L. CHENOT Ecole des Mines de Paris
G. DUVAUT Universite de Paris VI
E. £mATE Escuela Technica Superior de Ingenieros de
Caminos Canales y Puertos - Barcelone
M. PREDELEANU E.N.S.E.T. Cachan
J. L.M.S. - Ecole Poly technique
SALEN~ON
Organising Co.mittee
M. BELLET Ecole des Mines de Paris
C. LEVAILLANT Ecole des Mines de Paris
Eo MASSONI Ecole des Mines de Paris
P. MONTMITONNET Ecole des Mines de Paris
Colloquium Sponsors
ARMINES
ASSOCIATION UNIVERSITAIRE DE MECANIQUE
DIGITAL EQUIPEMENT CORPORATION
ECOLE DES MINES DE PARIS
I.R.S.I.D.
MICHELIN
PECHINEY
REGIE NATIONALE DES USINES RENAULT
TEKSID
TABLE OF CONTENTS
PART 1 : MATERIAL BEHAVIOUR
P. MAZILU, A. SKIADAS: The description of yield surfaces for cold
prestressed metals with the hypothesis of the isotropy centers translation 3
R.B. PECHERSKI: Constitutive description and numerical approach in
modelling for metal forming processes 11
G. DACKWEILER, E. EL-MAGD: Simulation of impact tension
deformation of metals by FEM. 19
G.J. CREUS, A.G. GROEHS: Finite elements analysis of large plastic
deformation in metals. 27
E. LUNDBACK, I. L. SVENSSON, P.E. PERSSON: Modelling of
structure formation and relation to mechanical properties of nodular cast iron. 37
PART 2 : NUMERICAL TECHNIQUES
L. CANNIZZARO, E. LO VALVO, F. MICARI, R. RICCOBONO: H and P
mesh refmement in the metal forming FEM analysis. 49
J. HUETINK, J. VAN DER LUGT, P.T. VREEDE: A mixed Eulerian-
Lagrangian FEM for simulation of thermo-mechanical forming processes. 57
J.P. PONTHOT: A method to reduce cost of mesh deformation in Eulerian-
Lagrangian formulation. 65
G.C. HUANG, Y.C. LIU, O.C. ZIENKIEWICZ: Error control, mesh
updating schemes and automatic adaptive remeshing for finite element
analysis of unsteady extrusion processes. 75
I. PILLINGER, P. HARTLEY, C.E.N. STURGESS: Modelling of frictional
tool surfaces in finite element metalforming analyses. 85
P. CHABRAND, Y. PINTO, M. RAOUS: Numerical modelling of friction
for metal forming processes. 93
PART 3 : SHEET METAL FORMING
D. BAUER: Modelling of deep drawing processes by model testing and
dimensional analysis. 103
H. VEGTER: A finite difference model as a basis for developing new
constitutive equations for the sheet forming process 111
E. DOEGE, M. SEYDEL: Influence of anisotropy in sheet metal forming 123
R.H. WAGONER, E. NAKAMACHI, Y. GERMAIN: Experience with
explicit and implicit fmite element programs for sheet forming analysis. 131
P. PIERRE, J.P. CORDEBOIS: Influence of thickness and curvature on the
formability of metal sheets. 139
G. PEROTTI, G. BELINGARDI, P.L. BELLARD!, M. GUIDA, A.
MESSINA, F. ZINGARIELLO: Experimental analysis of an axisymmetric
deep drawing. 147
viii
K. BERGSTROM, S. KIVIVUORI, S. OSENIUS, A. KORHONEN:
Computer aided design of a progressive die. 155
E. ONA lE, C. AGELET DE SARACIBAR: Finite element analysis of sheet
metal forming problems using a viscous voided shell formulation. 163
1. BONET, R.D. WOOD, O.C. ZIENKIEWICZ: Time stepping schemes for
the numerical analysis of superplastic forming of thin sheet 179
E. MASSONI, M. BELLET, 1.L. CHENOT: Thin sheet forming numerical
analysis with a membrane approach. 187
PART 4: FORGING AND DRAWING
G. SURDON, M. BAROUX: Comparison of simulation techniques and
industrial data in forging applications. 199
1.P. CESCUTTI, E. WEY, J.L. CHENOT, P.E. MOSSER: Finite Element
calculation of hot forging with continuous remeshing. 207
Y.T. 1M, S. KOBAYASHI: Finite element applications in forming billet and
P/M preforms. 217
N. SOYRIS, J.P. CESCUTII, T. COUPEZ, G. BRACHOTTE, 1.L.
CHENOT: Three dimensional finite element calculation of the forging of a
connecting rod. 227
P. GROCHE, U. WEISS: numerical identification of forging parameters. 237
N.L. DUNG: Identification of defect locations in metal forming using a
personal computer oriented finite element method. 245
A.N. BRAMLEY, F.H. OSMAN, M.I. GHOBRIAL: Modelling of metal
forming processes 253
I.M. RfGAUT, D. LOCHEGNIES, J. OUDIN, J.C. GELIN, Y.
RA VA LARD: Numerical analysis of cold drawing of tubes. 261
PART 5 : HOT AND COLD ROLLING
C. BERTRAND-CORSINI, C. DAVID, A. BERN, P. MONTMITONNET,
1.L. CHENOT, P. BUESSLER, F. FAU: A 3D thermomechanical analysis
of steady flows in hot forming processes. Application to hot flat rolling and
hot shape rolling. 271
M. PIETRZYK, I.G. LENARD: Thermal-mechanical modelling for hot
rolling: experimental substantiation. 281
F. FAU, P. BUESSLER, C.H. QUAN, C. BERTRAND: Simulation of hot
rolling of steel by plasticine or waxes. Comparison between the flow of steel
and the flow of plasticine by actual rolling and finite element models. 289
M. MALINEN, A. LANKILA, A.S. KORHONEN: Simulation of profile
and flatness in the cold rolling of steel strip. 297
O. PAWELSKI, W. RASP, 1. RIECKMAN: Application ofa mathematical
model for the cold rolling process on six-high mills. 305
MJ.M. BARATA MARQUES, P.A.F. MARTINS: Analysis of plane strain
cold rolling using a flow function and the weighted residuals method. 313
ix
1.H. BEYNON, A.R.S. PONTER, C. M. SELLARS: Metallographic
verification of computer modelling of hot rolling 321
P. HRYCAJ, D. LOCHEGNIES, 1. OUDIN, J.C. GELIN, Y.
RA VA LARD: Finite element analysis of two-roll hot piercing. 329
K.BAINES,I.M. COLE,D.H. SANSOME: Modelling the mechanics of the
longitudinal tube rolling process. 337
PART 1
MATERIAL BEHAVIOUR