Simulation of sheet metal deformation processes - Issues and challenges

Abstract

Finite Element (FE) simulation is commonly employed to predict deformation response and internal states of sheet metal and sheet metal structures. The accuracy of FE prediction relies among others, on the prescribed constitutive model and progressive damage model of the material. Inevitable simplifications of the problem through assumptions such as rigid body response, Coulomb friction law and axisymmetric conditions could affect both accuracy and jeopardize validity of the solution. Comparisons between calculated and measured variables provide validation of the FE model. In simulating fracture of sheet metal parts, both the mechanics and mechanisms of failure should be adequately reproduced. Subsequently, interpretation of FE results for desired information should be performed with knowledge of physics and mechanics of the material, along with good engineering judgment.