Shearing Process Simulation Using Element Strength Degradation
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Solution Overview
Problem
Existing metal forming simulation technologies fail to accurately predict the usability of sheared materials for consecutive engineering processes due to unreliable numerical preforms and inaccurate analysis of sheared surface quality, leading to inefficiencies in shearing, piercing, and blanking processes.
Innovation Solution
A new finite element method (FEM) incorporating an element strength degradation algorithm and sheared surface quality control system, which simulates shearing processes by generating a numerical preform or billet through finite element meshing, re-meshing, and node averaging, ensuring accurate prediction and usability of sheared materials in multi-stage metal forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional experimental or combined experimental-theoretical methods are used for shearing simulation, then basic shearing mechanisms can be elucidated, but the numerical preform cannot be reliably used for consecutive engineering processes
Solution Approach 1:
The patent applies parameter changes by modifying the element strength degradation model to account for compressive stress states. The flow stress parameters are adjusted based on the degree of damage and compressive stress, allowing the numerical preform to accurately represent the sheared material's mechanical properties for subsequent forming processes.
Solution Approach 2:
The patent introduces an intermediary damage variable that bridges the shearing process and consecutive forming processes. This damage variable is carried forward from the shearing simulation and used in subsequent forming simulations, enabling reliable prediction of multi-stage processes while maintaining numerical preform usability.
2Productivity
If element deletion method is used to simulate shearing, then shearing process can be simulated, but numerical issues occur and sheared surface quality cannot be controlled
Solution Approach 1:
Instead of deleting elements, the patent changes the state of elements by setting their strength parameters to near-zero values in the sheared region. This parameter change approach maintains the numerical mesh integrity while accurately representing the separated material, eliminating numerical issues associated with element deletion.
Solution Approach 2:
The patent applies preliminary action by pre-defining the shearing criteria and strength degradation parameters before the shearing process simulation. This allows the simulation to accurately predict the sheared surface quality and geometry without requiring post-processing or mesh regeneration.
3Ease of operation
If conventional shearing simulation is performed, then shearing process can be analyzed, but the impact on final product and consecutive stages cannot be analyzed
Solution Approach 1:
The patent creates a universal numerical preform that can be used across multiple forming processes. The damage-based element strength degradation model is applicable to both shearing and subsequent forming operations, allowing the same simulation framework to analyze the entire multi-stage process from shearing to final product formation.
Solution Approach 2:
The damage variable serves as an intermediary that connects the shearing process analysis with consecutive process analysis. By carrying forward the damage state from shearing simulations, the patent enables seamless transition to subsequent forming process simulations, maintaining ease of operation while gaining versatility.
4Productivity
If sheared material is used in consecutive forming processes, then multi-stage metal forming can be simulated, but inaccurate prediction of surface quality and usability occurs
Solution Approach 1:
The patent applies parameter changes by adjusting the flow stress and strength parameters of elements based on their damage state. Elements in the sheared region have modified parameters that reflect the actual material condition, enabling accurate prediction of surface quality and usability in consecutive forming processes while maintaining simulation productivity.
Data Source
AI summary
A shearing process simulation method may include a first step in which a finite element and a node are generated in a raw material, a second step in which a fracture surface is calculated for a sheared material with a shearing force applied to the raw material, a third step in which an element of the sheared material is divided into a first group and a second group with the fracture surface as a boundary, a fourth step in which an average value is obtained by averaging information of a second group element or a second group node included in the second group, and a fifth step in which a final fracture surface is generated by reflecting the average value in the fracture surface.