Finite element (FE)–based studies of preoperative processes such as folding, pleating, and stent crimping with a comparison with experimental inflation tests are not yet available. Therefore, a novel workflow is presented in which residual stresses of balloon folding and pleating, as well as stent crimping, and the geometries of all contact partners were ultimately implemented in an FE code to simulate stent expansion by using an implicit solver. The numerical results demonstrate that the incorporation of residual stresses and strains experienced during the production step significantly increased the accuracy of the subsequent simulations, especially of the stent expansion model. During the preoperative processes, stresses inside the membrane and the stent material also reached a rather high level. Hence, there can be no presumption that balloon catheters or stents are undamaged before the actual surgery. The implementation of the realistic geometry, in particular the balloon tapers, and the blades of the process devices improved the simulation of the expansion mechanisms, such as dogboning, concave bending, or overexpansion of stent cells. This study shows that implicit solvers are able to precisely simulate the mentioned preoperative processes and the stent expansion procedure without a preceding manipulation of the simulation time or physical mass.
Press hardening is a well-established production process in the automotive industry today. The actual trend of this process technology points towards the manufacturing of parts with tailored properties. Since the knowledge of the mechanical properties of a structural part after forming and quenching is essential for the evaluation of for example the crash performance, an accurate as possible virtual assessment of the production process is more than ever necessary. In order to achieve this, the definition of reliable input parameters and boundary conditions for the thermo-mechanically coupled simulation of the process steps is required. One of the most important input parameters, especially regarding the final properties of the quenched material, is the contact heat transfer coefficient (IHTC). The CHTC depends on the effective pressure or the gap distance between part and tool. The CHTC at different contact pressures and gap distances is determined through inverse parameter identification. Furthermore a simulation strategy for the subsequent steps of the press hardening process as well as adequate modeling approaches for part and tools are discussed. For the prediction of the yield curves of the material after press hardening a phenomenological model is presented. This model requires the knowledge of the microstructure within the part. By post processing the nodal temperature history with a CCT diagram the quantitative distribution of the phase fractions martensite, bainite, ferrite and pearlite after press hardening is determined. The model itself is based on a Hockett-Sherby approach with the Hockett-Sherby parameters being defined in function of the phase fractions and a characteristic cooling rate.
To increase the accuracy of finite element simulations in daily practice the local German and Austrian Deep Drawing Research Groups of IDDRG founded a special Working Group in year 2000. The main objective of this group was the continuously ongoing study and discussion of numerical / material effects in simulation jobs and to work out possible solutions. As a first theme of this group the intensive study of small die radii and the possibility of detecting material failure in these critical forming positions was selected. The part itself is a fictional body panel outside in which the original door handle of the VW Golf A4 has been constructed, a typical position of possible material necking or rupture in the press shop. All conditions to do a successful simulation have been taken care of in advance, material data, boundary conditions, friction, FLC and others where determined for the two materials in investigation-a mild steel and a dual phase steel HXT500X. The results of the experiments have been used to design the descriptions of two different benchmark runs for the simulation. The simulations with different programs as well as with different parameters showed on one hand negligible and on the other hand parameters with strong impact on the result-thereby having a different impact on a possible material failure prediction.
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