Numerical investigation of multi-point forming process for sheet metal: wrinkling, dimpling and springback

Multi-point forming (MPF) is a new flexible technique for manufacturing three-dimensional sheet metal parts. In this procedure, a pair of opposed matrices of punch elements substitute for the conventional fixed shape die sets, and the sheet metal can be formed rapidly between the matrices. Extensive...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2008-06, Vol.37 (9-10), p.927-936
Main Authors: Cai, Zhong-Yi, Wang, Shao-Hui, Li, Ming-Zhe
Format: Article
Language:English
Subjects:
Algorithms
CAE) and Design
Computer simulation
Computer-Aided Engineering (CAD
Dimpling
Engineering
Finite element method
Industrial and Production Engineering
Investigations
Mathematical analysis
Mechanical Engineering
Media Management
Metal sheets
Numerical analysis
Original Article
Product design
Springback
Wrinkling
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Summary:Multi-point forming (MPF) is a new flexible technique for manufacturing three-dimensional sheet metal parts. In this procedure, a pair of opposed matrices of punch elements substitute for the conventional fixed shape die sets, and the sheet metal can be formed rapidly between the matrices. Extensive numerical simulations of the processes for forming spherical and saddle-shaped parts were carried out by dynamic explicit finite element analysis. The contacting process between sheet metal and punch elements in MPF was investigated, and the variations of forming force with respect to the tool travel were analyzed. The wrinkling processes were simulated, and the MPF limit curves without wrinkles for spherical and saddle-shaped parts were obtained. Dimple is a particular defect in MPF, through the comparison of the thickness strains calculated by solid FE and shell FE, the finite elements appropriate for the numerical analysis of dimpling were detected, and the limit forming force without dimples was determined. Springback processes of MPF were simulated based on explicit-implicit algorithm. The springbacks and their distributions under different conditions were investigated.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-007-1045-5