Accurate product model development for the simulation of the dynamic behaviour of deep drawn components

Developing an accurate product model is a crucial task for the numerical simulation of the dynamic behavior of mechanical components. In this setting, this work considers the specific case of components manufactured through a deep drawing process. Because of the large deformations involved, a thickness variation is obtained in the final manufactured component with respect to the initial blank thickness, which has to be accounted for in order to have an adequate model for numerical analysis. Furthermore, the intrinsic variability of the process and local variations of the stiffness, due to plastic hardening and residuals stresses, give rise to nominally identical components with different dynamic properties, especially at high frequencies. Two simulation frameworks are considered in this study for the product model development: the first one is based on a purely numerical approach, where the dynamic simulation is performed on a model obtained from a finite element simulation of the forming process. The second one considers a reverse engineering framework, where the product model is computed by a surface reconstruction procedure starting from laser scan measurements on the manufactured component; this reverse engineering procedure can be realized either by (i) a triangular surface reconstruction that forms the starting point to obtain a finite element mesh of the component or by (ii) fitting a smooth B-spline surface on the point cloud data that can be used directly for the analysis employing the paradigm of isogeometric analysis (IGA). The different approaches are applied to predict the dynamic behaviour of an axis-symmetric deep drawn steel cup and are validated with experimental measurements. Finally, it is shown how a model updating procedure of the stiffness can be easily implemented in the framework of IGA, which can further improve the accuracy of the product model.

ISBN:9789073802995

Publication year:2018

BOF-keylabel:yes

IOF-keylabel:yes

Authors from:Government, Higher Education

Accessibility:Closed