In this work, a fully adaptive 2D numerical methodology is proposed in order to simulate with accuracy various metal forming processes. The methodology is based on fully coupled advanced finite strain constitutive equations accounting for the main physical phenomena such as large plastic deformation, non-linear isotropic and kinematic hardening, ductile isotropic damage and contact with friction. The adaptivity concerns the space discretization using FEM as well as the applied loading sequences. Mesh size distribution is based on various error indicators making use of the hessian of the plastic strain rate combined with a specific damage error function and a specific local curvature error function evaluated at contact boundaries. 2D mesh size can be refined or coarsened when necessary according to these error indicators. Particularely, the smallest size is found to be inside the zones where the damage is highly active. The applied loading paths are also adaptively decomposed into various sequences depending on both number and size of the fully damaged elements. The adaptive procedure is validated through various sheet and bulk metal forming examples. In this paper, a plane stress tensile test, an axisymmetric blanking process of two materials with different ductilities and a cold extrusion process are presented.
The micromorphic constitutive model developed in previous works and accounting for isotropic plasticity, mixed kinematic and isotropic hardening and micromorphic damage is revised in order to enhance some coupling aspects. The associated numerical aspects are investigated and implemented into ABAQUS®/Explicit solver by developing two subroutines VUMAT to implement the micromorphic model and VUEL to implement an assumed strain-based element with additional micromorphic degrees of freedom. The tensional and bending tests of DP1000 dual phase steel are simulated and used to validate the model by comparing with experimental results.
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