Effect of Mesh on Springback in 3D Finite Element Analysis of Flexible Microrolling

Abstract

In flexible microrolling, springback in thickness direction is a critical indicator to determine the forming quality. Accurate prediction of springback is one of the significant aspects in the finite element analysis of flexible microrolling. Meshing is a step of great importance in finite element analysis of manufacturing process as it directly determines the accuracy of the FEA results as well as the requested computational time. This paper presents a numerical study on revealing the mesh effects on the accuracy of springback estimation utilising ABAQUS/Standard for modelling and analyses. Two types of meshes with six mesh sizes for each mesh type are considered in this study and the optimal mesh type and mesh size have been found to obtain accurate value of springback while saving as much computational time as possible.

Effect of Friction on Buckling Behavior in Shallow Spherical to Hemispherical Shells in Contact with Rigid Boundaries under Uniform External Pressure

“…The accuracy of the numerical simulation is significantly influenced by mesh size. However, an excessively fine mesh can result in increased computational time and cost [36,37]. Therefore, a mesh convergence study is initially conducted to determine an appropriate mesh size.…”

Study of micro flexible rolling based on grained inhomogeneity

“…Substituting Equations (49) and (50) into Equation (48) and using the fact that the components of the virtual displacement are arbitrary yield the finite element system equilibrium equation:…”

“…Material behaviour of this type is termed springback, e.g., a slight decrease in the bending angle after the V-bending process, a slight increase in the flange angle after the deep drawing process, etc., which are affected by the factors such as process parameters, material properties and tooling geometries and have a chance of being compensated by overbending the material [29,35,[42][43][44][45]. Whilst for the strip rolling process springback may refer to the elastic recovery in the thickness after the strip exits the roll bite, and it is likely to be rectified by dint of increasing the rolling speed, adding tensions to the strip, decreasing the roll gap for a supplementary amount of reduction, and so forth [46][47][48][49][50]. In this context, analytical techniques are introduced firstly to construct mathematical models respecting the rolling force and the thickness directional springback of the workpiece in micro flexible rolling, integrating the influential role played by inhomogeneous grains; micro hardness tests are conducted to determine the weighted heterogeneity coefficients for the 500 μm thick aluminium alloy 1060 strips with various average grain sizes, which reflect the inhomogeneous nature of the grains in each specimen separately.…”

Analysis of Springback Behaviour in Micro Flexible Rolling of Crystalline Materials

“…However, thanks to the increasing popularity of miniaturisation in modern industrial development over recent years, it has been promising to look into the flexible rolling process of micrometer thick materials, whereof the overall dimensions as well as the longitudinal thickness profiles of the workpieces may be adapted to the requirements of the microapparatus and systems. Pioneering investigations into the microflexible rolling process have been conducted with respect to the rolling force, the elastic recovery in thickness direction of the workpiece, the surface roughness evolution related to different process variables, and so forth [3][4][5][6]. Due to the thinness of the material, the thickness directional springback of the rolled workpiece, mainly caused by the elastic redistribution of the internal stresses upon removal of the rolling force, can lead to failure to produce a predefined thickness profile along rolling direction [7].…”