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Specific features of FE-Meshes for the Analysis of metal forming processes

Autoren:Doege, E.; Meinen, J.
Kategorie:Zeitschriften/Aufsätze (reviewed)
Jahr:2000
Veröffentlichung:Engineering Research, Springer-VDI-Verlag, 66 (2000), Nr. 1, pp. 40-48

Abstract

Due to steadily increasing demands on the die forging industry, process simulation is of continuous importance. The Finite Element Method (FEM) is frequently used to simulate forming processes for the purpose of optimising the quality of the final product and predicting the loading on the tool. Most forgoing processes reduce the original height of the workpiece by 60–70%. Therefore, considerable distortions of the finite element mesh occur and some elements can even degenerate. Consequently, the results obtained are unreliable and sometimes it is impossible to pursue the calculation any further. In order to continue the analysis, it becomes necessary to define a new mesh during the FE-simulation (remeshing). The loss of volume of the new mesh is a very critical point. In this paper an algorithm to mesh complex 3D geometries with tetrahedron elements (FORM TET) is presented, which is taking into account the specific aspects of metal forming processes and increases the loss of volume in FE-analysis. This algorithm creates a mesh that meets the requirements of the object. As illustrated in the presented examples, the elaborated strategy ensures a robust and efficient meshing scheme. To verify the efficiency of this remeshing concept some fundamental metal forming processes have been simulated.