DEFORMATION ANALYSIS OF SHEET METAL SINGLE-POINT INCREMENTAL FORMING BY FINITE ELEMENT METHOD SIMULATION

Single-point incremental forming （SPIF） is an innovational sheet metal forming method without dedicated dies, which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal, the deformation analysis on forming process becomes an important and useful method for the planning of shell products, the choice of material, the design of the forming process and the planning of the forming tool. Using solid brick elements, the finite element method（FEM） model of truncated pyramid was established. Based on the theory of anisotropy and assumed strain formulation, the SPIF processes with different parameters were simulated. The resulted comparison between the simulations and the experiments shows that the FEM model is feasible and effective. Then, according to the simulated forming process, the deformation pattern of SPIF can be summarized as the combination of plane-stretching deformation and bending deformation. And the study about the process parameters＇ impact on deformation shows that the process parameter of interlayer spacing is a dominant factor on the deformation. Decreasing interlayer spacing, the strain of one step decreases and the formability of blank will be improved. With bigger interlayer spacing, the plastic deformation zone increases and the forming force will be bigger.

Texture evolution and inhomogeneous deformation of polycrystalline Cu based on crystal plasticity finite element method and particle swarm optimization algorithm

Texture evolution and inhomogeneous deformation of polycrystalline Cu during uniaxial compression are investigated at the grain scale by combining crystal plasticity finite element method(CPFEM) with particle swarm optimization(PSO) algorithm. The texture-based representative volume element(TBRVE) is used in the crystal plasticity finite element model, where a given number of crystallographic orientations are obtained by means of discretizing the orientation distribution function(ODF) based on electron backscattered diffraction(EBSD) experiment data. Three-dimensional grains with different morphologies are generated on the basis of Voronoi tessellation. The PSO algorithm plays a significant role in identifying the material parameters and saving computational time. The macroscopic stress–strain curve is predicted based on CPFEM, where the simulation results are in good agreement with the experimental ones. Therefore, CPFEM is a powerful candidate for capturing the texture evolution and clarifying the inhomogeneous plastic deformation of polycrystalline Cu. The simulation results indicate that the <110> fiber texture is generated finally with the progression of plastic deformation. The inhomogeneous distribution of rotation angles lays the foundation for the inhomogeneous deformation of polycrystalline Cu in terms of grain scale.

Finite element method for coupled diffusion-deformation theory in polymeric gel based on slip-link model

A polymeric gel is an aggregate of polymers and solvent molecules, which can retain its shape after a large deformation. The deformation behavior of polymeric gels was often described based on the Flory-Rehner free energy function without considering the influence of chain entanglements on the mechanical behavior of gels. In this paper,a new hybrid free energy function for gels is formulated by combining the EdwardsVilgis slip-link model and the Flory-Huggins mixing model to quantify the time-dependent concurrent process of large deformation and mass transport. The finite element method is developed to analyze examples of swelling-induced deformation. Simulation results are compared with available experimental data and show good agreement. The influence of entanglements on the time-dependent deformation behavior of gels is also demonstrated.The study of large deformation kinetics of polymeric gel is useful for diverse applications.

Surrounding rock deformation analysis of underground caverns with multi-body finite element method

Discontinuous deformation problems are common in rock engineering. Numerical analysis methods based on system models of the discrete body can better solve these problems. One of the most effective solutions is discontinuous deformation analysis （DDA） method, but the DDA method brings about rock embedding problems when it uses the strain assumption in elastic deformation and adopts virtual springs to simulate the contact problems. The multi-body finite element method （FEM） proposed in this paper can solve the problems of contact and deformation of blocks very well because it integrates the FEM and multi-body system dynamics theory. It is therefore a complete method for solving discontinuous deformation problems through balance equations of the contact surface and for simulating the displacement of whole blocks. In this study, this method was successfully used for deformation analysis of underground caverns in stratified rock. The simulation results indicate that the multi-body FEM can show contact forces and the stress states on contact surfaces better than DDA, and that the results calculated with the multi-body FEM are more consistent with engineering practice than those calculated with DDA method.

A dynamic large-deformation particle finite element method for geotechnical applications based on Abaqus

In this paper,the application of Abaqus-based particle finite element method(PFEM)is extended from static to dynamic large deformation.The PFEM is based on periodic mesh regeneration with Delaunay triangulation to avoid mesh distortion.Additional mesh smoothing and boundary node smoothing techniques are incorporated to improve the mesh quality and solution accuracy.The field variables are mapped from the old to the new mesh using the closest point projection method to minimize the mapping error.The procedures of the proposed Abaqus-based dynamic PFEM(Abaqus-DPFEM)analysis and its implementation in Abaqus are detailed.The accuracy and robustness of the proposed approach are examined via four illustrative numerical examples.The numerical results show a satisfactory agreement with published results and further confirm the applicability of the Abaqus-DPFEM to solving dynamic large-deformation problems in geotechnical engineering.

ANALYSIS OF ROLLING BY ELASTO-PLASTIC FINITE DEFORMATION CONTACT BOUNDARY ELEMENT METHOD

A multinonlinear boundary element method is established dealing with elasto plastic finite deformation contact problem, and it is employed to analysis rolling process. With rollers as elastic bodies, workpieces as elastio plastic bodies, rolling problem can be viewed as a frictional elasto plastic contact problem. With fewer assumptions in the simulation of the rolling process, a novel and accurate method is proposed for analysis of rolling problems.

THE RANDOM VARIATIONAL PRINCIPLE IN FINITE DEFORMATION OF ELASTICITY AND FINITE ELEMENT METHOD

In the present paper, we hare mtroduced the random materials. loads. geometricalshapes, force and displacement boundary condition directly. into the functionalvariational formula, by. use of a small parameter perturbation method, a unifiedrandom variational principle in finite defomation of elastieity and nonlinear randomfinite element method are esiablished, and used.for reliability, analysis of structures.Numerical examples showed that the methods have the advontages of simple andconvenient program implementation and are effective for the probabilistic problems inmechanics.

Numerical Simulation of Surrounding Rock Deformation and Grouting Reinforcement of Cross-Fault Tunnel under Different Excavation Methods

Tunnel construction is susceptible to accidents such as loosening, deformation, collapse, and water inrush, especiallyunder complex geological conditions like dense fault areas. These accidents can cause instability and damageto the tunnel. As a result, it is essential to conduct research on tunnel construction and grouting reinforcementtechnology in fault fracture zones to address these issues and ensure the safety of tunnel excavation projects. Thisstudy utilized the Xianglushan cross-fault tunnel to conduct a comprehensive analysis on the construction, support,and reinforcement of a tunnel crossing a fault fracture zone using the three-dimensional finite element numericalmethod. The study yielded the following research conclusions: The excavation conditions of the cross-fault tunnelarray were analyzed to determine the optimal construction method for excavation while controlling deformationand stress in the surrounding rock. The middle partition method (CD method) was found to be the most suitable.Additionally, the effects of advanced reinforcement grouting on the cross-fault fracture zone tunnel were studied,and the optimal combination of grouting reinforcement range (140°) and grouting thickness (1m) was determined.The stress and deformation data obtained fromon-site monitoring of the surrounding rock was slightly lower thanthe numerical simulation results. However, the change trend of both sets of data was found to be consistent. Theseresearch findings provide technical analysis and data support for the construction and design of cross-fault tunnels.

Validation and application of three-dimensional discontinuous deformation analysis with tetrahedron finite element meshed block

In the last decade, three dimensional discontin- uous deformation analyses （3D DDA） has attracted more and more attention of researchers and geotechnical engineers worldwide. The original DDA formulation utilizes a linear displacement function to describe the block movement and deformation, which would cause block expansion under rigid body rotation and thus limit its capability to model block de- formation. In this paper, 3D DDA is coupled with tetrahe- dron finite elements to tackle these two problems. Tetrahe- dron is the simplest in the 3D domain and makes it easy to implement automatic discretization, even for complex topol- ogy shape. Furthermore, element faces will remain planar and element edges will remain straight after deformation for tetrahedron finite elements and polyhedral contact detection schemes can be used directly. The matrices of equilibrium equations for this coupled method are given in detail and an effective contact searching algorithm is suggested. Valida- tion is conducted by comparing the results of the proposed coupled method with that of physical model tests using one of the most common failure modes, i.e., wedge failure. Most of the failure modes predicted by the coupled method agree with the physical model results except for 4 cases out of the total 65 cases. Finally, a complex rockslide example demon- strates the robustness and versatility of the coupled method.

Die structure optimization of equal channel angular extrusion for AZ31 magnesium alloy based on finite element method

Three-dimensional（3D） geometric models with different comer angles （90° and 120°） and with or without inner round fillets in the bottom die were designed. Some important process parameters were regarded as the calculation conditions used in DEFORMTM-3D software, such as stress--strain data of compression test for AZ31 magnesium, temperatures of die and billet, and friction coefficient. Influence of friction coefficient on deformation process was discussed. The results show that reasonable lubrication condition is important to plastic deformation. The change characteristics for distributions of effective stress and strain during an equal channel angular extrusion （ECAE） process with inner angle of 90° and without fillets at outer comer were described. Inhomogeneity index （C） was defined and deformation heterogeneity of ECAE was analyzed from the simulation and experiment results. The deformation homogeneity caused by fillets at outer comer increased compared with the die without fillets. The cumulated maximum strains decrease with increasing the fillets of outer comer in ECAE die and the inner comer angle. The analysis results show that better structures of ECAE die including appropriate outer comer fillet and the inner comer angle of 90° for the die can improve the strain and ensure plastic deformation homogenization to a certain extent. The required extrusion force drops with increasing the fillet made at outer comer in ECAE die. It is demonstrated that the prediction results are in good agreement with experiments and the theoretical calculation and the research conclusions in literatures.

Prediction of grain scale plasticity of NiTi shape memory alloy based on crystal plasticity finite element method

Grain scale plasticity of NiTi shape memory alloy(SMA)during uniaxial compression deformation at 400℃was investigated through two-dimensional crystal plasticity finite element simulation and corresponding analysis based on the obtained orientation data.Stress and strain distributions of the deformed NiTi SMA samples confirm that there exhibits a heterogeneous plastic deformation at grain scale.Statistically stored dislocation(SSD)density and geometrically necessary dislocation(GND)density were further used in order to illuminate the microstructure evolution during uniaxial compression.SSD is responsible for sustaining plastic deformation and it increases along with the increase of plastic strain.GND plays an important role in accommodating compatible deformation between individual grains and thus it is correlated with the misorientation between neighboring grains,namely,a high GND density corresponds to large misorientation between grains and a low GND density corresponds to small misorientation between grains.

Finite Element Analysis for Effect of Roll Radius on Metal Deformation of Hot Rolling Plate

The deformation of rolling piece in hot rolling by flat roll with different radii is analyzed with three-dimensional large deformation thermo-mechanical coupling finite element method.The distribution laws of stress,strain and strain energy density in deformation zone with rolls of different radii were studied.The result indicated that under the same condition,the larger the roll radius is,the more vigorous the deformation in deformation zone is.

Thermo-hydro-mechanical-air coupling finite element method and its application to multi-phase problems

In this paper, a finite element method （FEM）-based multi-phase problem based on a newly proposed thermal elastoplastic constitutive model for saturated/unsaturated geomaterial is discussed. A program of FEM named as SOFT, adopting unified field equations for thermo-hydro-mechanical-air （THMA） behavior of geomaterial and using finite element-finite difference （FE-FD） scheme for so/l-water-air three-phase coupling problem, is used in the numerical simulation. As an application of the newly proposed numerical method, two engineering problems, one for slope failure in unsaturated model ground and another for in situ heating test related to deep geological repository of high-level radioactive waste （HLRW）, are simulated. The model tests on slope failure in unsaturated Shirasu ground, carried out by Kitamura et al. （2007）, is simulated in the framework of soil-water-air three-phase coupling under the condition of constant temperature. While the in situ heating test reported by Munoz （2006） is simulated in the same framework under the conditions of variable temperature hut constant air pressure.

PREDICTION FOR FORMING LIMIT OF AL2024T3 SHEET BASED ON DAMAGE THEORY USING FINITE ELEMENT METHOD

This paper presents the application of anisotropic damage theory to the study of forming limit diagram of A12024T3 aluminum alloy sheet. In the prediction of limiting strains of the aluminum sheet structure, a finite element cell model has been constructed. The cell model consists of two phases, the aluminum alloy matrix and the intermetallic cluster. The material behavior of the aluminum alloy matrix is described with a fully coupled elasto-plastic damage constitutive equation. The intermetallic cluster is assumed to be elastic and brittle. By varying the stretching ratio, the limiting strains of the sheet under biaxial stretching have been predicted by using the necking criterion proposed. The prediction is in good agreement with the experimental findings. Moreover, the finite element cell model can provide information for understanding the microscopic damage mechanism of the aluminum alloy. Over-estimation of the limit strains may result if the effect of material damage is ignored in the sheet metal forming study.

Simulation of bulk metal forming processes using one-step finite element approach based on deformation theory of plasticity

The bulk metal forming processes were simulated by using a one-step finite element(FE)approach based on deformation theory of plasticity,which enables rapid prediction of final workpiece configurations and stress/strain distributions.This approach was implemented to minimize the approximated plastic potential energy derived from the total plastic work and the equivalent external work in static equilibrium,for incompressibly rigid-plastic materials,by FE calculation based on the extremum work principle.The one-step forward simulations of compression and rolling processes were presented as examples,and the results were compared with those obtained by classical incremental FE simulation to verify the feasibility and validity of the proposed method.

Cracking Propagation of Hardening Concrete Based on the Extended Finite Element Method

Self-deformation cracking is the cracking caused by thermal deformation, autogenous volume deformation or shrinkage deformation. In this paper, an extended finite element calculation method was deduced for concrete crack propagation under a constant hydration and hardening condition during the construction period, and a corresponding programming code was developed. The experimental investigation shows that initial crack propagation caused by self-deformation loads can be analyzed by this program. This improved algorithm was a preliminary application of the XFEM to the problem of the concrete self-deformation cracking during the hydration and hardening period. However, room for improvement exists for this algorithm in terms of matching calculation programs with mass concrete temperature fields containing cooling pipes and the influence of creep or damage on crack propagation.

FINITE ELEMENT ANALYSIS OF SUBSTRATE LOCAL PLASTIC DEFORMATION INDUCED BY CRACKED THIN HARD FILM

It has been postulated that, with tensile loading conditions, micro-cracks onthin hard film act as stress concentrators enhancing plastic deformation of the substrate materialin their vicinity. Under favorable conditions the localized plastic flow near the cracks may turninto macroscopic plastic strain thus affects the plasticity behaviors of the substrate. Thisphenomenon is analyzed quantitatively with finite element method with special attention focused onthe analysis and discussion of the effects of plastic work hardening rate, film thickness and crackdepth on maximum plastic strain, critical loading stress and the size of the local plasticdeformation zone. Results show that micro-cracks on thin hard film have unnegligible effects on theplasticity behaviors of the substrate material under tensile loading.

Least Square Finite Element Method for Viscous Splitting of Unsteady Incompressible Navier–Stokes Equations

In order to solve unsteady incompressible Navier–Stokes(N–S) equations, a new stabilized finite element method,called the viscous-splitting least square FEM, is proposed. In the model, the N–S equations are split into diffusive and convective parts in each time step. The diffusive part is discretized by the backward difference method in time and discretized by the standard Galerkin method in space. The convective part is a first-order nonlinear equation.After the linearization of the nonlinear part by Newton’s method, the convective part is also discretized by the backward difference method in time and discretized by least square scheme in space. C0-type element can be used for interpolation of the velocity and pressure in the present model. Driven cavity flow and flow past a circular cylinder are conducted to validate the present model. Numerical results agree with previous numerical results, and the model has high accuracy and can be used to simulate problems with complex geometry.

Numerical Simulation of Stress-Strain State for Nonhomogeneous Shell-Type Structures Based on the Finite Element Method

Projective-iterative version of finite element method has developed for numerical simulation of the stress-strain state of nonhomogeneous shell-type structures (shells with openings). Plastic deformation of the material is taken into account when using the method of elastic solutions that reduce the solution of elastoplastic problems to solution of elastic problems. Developed PIV’s significant savings of computer calculation has been compared with the calculation on a fine mesh of traditional FEM. Designed scheme allows analysis of the mutual influence of openings. Analysis of the transformation zone of plastic deformation is developed. For definiteness, the cylindrical shell structures with several rectangular openings are considered.

Finite element modeling to study flow induced deformation of biofilm

Fluid flow past the biofilm surface can bring external force to biofilm which could result in biofilm deformation and detachment. The flow velocity have significant effect on determining biofilm deformation and detachment. In this work, finite element method was adapted to study the flow induced deformation of biofilm in varied flow conditions.