The use of Finite Element (FE) simulation software to adequately predict the outcome of sheet metal forming processes is crucial to enhancing the efficiency and lowering the development time of such processes, whilst reducing costs involved in trial-and-error prototyping. Recent focus on the substitution of steel components with aluminum alloy alternatives in the automotive and aerospace sectors has increased the need to simulate the forming behavior of such alloys for ever more complex component geometries. However these alloys, and in particular their high strength variants, exhibit limited formability at room temperature, and high temperature manufacturing technologies have been developed to form them. Consequently, advanced constitutive models are required to reflect the associated temperature and strain rate effects. Simulating such behavior is computationally very expensive using conventional FE simulation techniques. This paper presents a novel Knowledge Based Cloud FE (KBC-FE) simulation technique that combines advanced material and friction models with conventional FE simulations in an efficient manner thus enhancing the capability of commercial simulation software packages. The application of these methods is demonstrated through two example case studies, namely: the prediction of a material's forming limit under hot stamping conditions, and the tool life prediction under multi-cycle loading conditions.
Abstract. In the present research, the friction and wear behaviour of a hard coating were studied by using ball-on-disc tests to simulate the wear process of the coated tools for sheet metal forming process. The evolution of the friction coefficient followed a typical dualplateau pattern, i.e. at the initial stage of sliding, the friction coefficient was relatively low, followed by a sharp increase due to the breakdown of the coatings after a certain number of cyclic dynamic loadings. This phenomenon was caused by the interactive response between the friction and wear from a coating tribo-system, which has not been addressed so far by metal forming researchers, and constant friction coefficient values are normally used in the FE simulations to represent the complex tribological nature at the contact interfaces. Meanwhile, most of the current FE simulations are single cycle, whereas most sheet metal forming operations are conducted as multi-cycle. Therefore, a novel friction/wear interactive friction model was developed to, simultaneously, characterise the evolutions of friction coefficient and the remaining thickness of the coating layer, to enable the wear life of coated tooling to be predicted. The friction model was then implemented into the FE simulation of a sheet metal forming process for feasibility study.
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