Fast resolution of incremental forming processes by the Multi-Mesh method. Application to cogging
Source abstract
Abstract
A Multi-Mesh Multi-Physics (MMMP) method is developed to reduce the very long computational time required for simulating incremental forming processes such as cogging or ring rolling. It consists in using several finite element meshes on the same domain to solve the different physics of the problem. A reference mesh is used to accurately store the results and history variables, while the different computational meshes are optimized to solve each physic of the problem. The MMMP algorithm consists in two main key-steps: the generation of the different unstructured meshes and the data transfer between the meshes. The accuracy of the method is supported by using meshes that are embedded by nodes. The method is applied to the simulation of the cogging metal forming process for which it shows as accurate and more than ten times faster than the standard method with a single mesh.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Metal Forming Simulation Techniques · Metallurgy and Material Forming · Fluid Dynamics Simulations and Interactions
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (31)
Show source-provided references
1. Groche P, Fritsche D, Tekkaya EA, Allwood JM, Hirt G, Neugebauer R (2007) Incremental Bulk Metal Forming. CIRP Ann Manuf Technol 56(2):635–65610.1016/j.cirp.2007.10.006 ↗
2. Chenot JL (1989) Three dimensional finite element modeling of forging process. Computational Plasticity Pineridge press, Swansea, pp 793–816
3. Hadoush A, Van den Boogaard AH (2008) Time reduction in implicit single point incremental sheet forming simulation by refinement-derefinement. Int J Mater Form 1(1):1167–117010.1007/s12289-008-0188-8 ↗
4. Hadoush A, Van den Boogaard AH (2009) Substructuring in the implicit simulation of single point incremental sheet forming. Int J Mater Form 2(3):181–18910.1007/s12289-009-0402-3 ↗
5. El Hadj M (1987) Application des méthodes multi-grilles aux calculs des structures élastiques et visco-plastiques. Ph.D. Thesis, Mines Paristech, France
6. Le Dain M A (1991) Méthodes multigrille et H-adaptation : application au calcul de structures élastiques bidimensionnelles. Ph.D. Thesis, Mines Paristech, France
7. Mocellin K, Fourment L, Coupez T, Chenot JL (2001) Toward large scale F.E. computation of hot forging process using iterative solvers, parallel computation and multigrid algorithms. Int J Numer Meth Eng 52(5–6):473–48810.1002/nme.304 ↗
8. Rey B, Mocellin K, Fourment L (2008) A node-nested Galerkin multigrid method for metal forging simulation. Comput Visual Sci 11(1):17–2510.1007/s00791-006-0054-5 ↗
9. Ramadan M (2010) Une Méthode MultiMaillages MultiPhysiques Parallèles pour accélérer les calculs des procédés multiphysiques incrémentaux. Ph.D. Thesis, Mines Paristech, France
10. Rannou J, Gravouil A, Baïetto-Dubourg MC (2007) Éléments finis étendus multi-grilles avec raffinement local pour la mécanique de la rupture. Acte du 8ème Colloque National en Calcul des Structures 1:69–74, Giens France
11. Kim NS, Machida S, Kobayashi S (1990) Ring rolling process simulation by the three dimensional finite element method. Int J Mach Tools Manuf 30(4):569–57710.1016/0890-6955(90)90008-7 ↗
12. Hu ZM, Pillinger I, Hartley P, McKenzie S, Spence PJ (1994) Three dimensional finite-element modeling of ring rolling. J Mater Process Technol 45(1–4):143–148
13. Keun Moon H, Cheol Lee M, Soo Joun M (2008) Predicting polygonal-shaped defects during hot ring rolling using a rigid-viscoplastic finite element method. Int J Mech Sci 50:306–31410.1016/j.ijmecsci.2007.06.004 ↗
14. Barton G, Li X, Hirt G (2007) Finite-element modeling of multi-pass forging of nickel-base alloys using a Multi-Mesh method. Mater Sci Forum 539–543:2503–250810.4028/www.scientific.net/MSF.539-543.2503 ↗
15. Hirt G, Kopp R, Hofmann O, Franzke M, Barton G (2007) Implementing a high accuracy Multi-Mesh Method for incremental Bulk Metal Forming. CIRP Ann Manuf Technol 56(1):313–31610.1016/j.cirp.2007.05.072 ↗
16. Li R (2005) On Multi-Mesh h-adaptive methods. J Sci Comput 24(3):321–34110.1007/s10915-004-4793-5 ↗
17. Hu X, Li R, Tang T (2009) A Multi-Mesh adaptive finite element approximation to phase field models. Comm Comput Phys 5(5):1012–1029
18. Di Y, Wang XP (2009) Precursor simulations in spreading using a Multi-Mesh adaptive finite element method. J Comput Phys 228(5):1380–139010.1016/j.jcp.2008.10.028 ↗
19. Terzolo L (2004) Vers une prédiction de la durée de vie des outils de forge à chaud par la modélisation numérique du régime thermique et de l’usure abrasive. Ph.D. Thesis, Mines Paristech, France
20. Arnold DN, Brezzi F, Fortin M (1984) A stable finite element for the Stokes equations. Calcolo 21(4):337–34410.1007/BF02576171 ↗
21. Fourment L, Chenot JL, Mocellin K (1999) Numerical formulations and algorithms for solving contact problems in metal forming simulation. Int J Numer Meth Eng 46(9):1435–146210.1002/(SICI)1097-0207(19991130)46:9<1435::AID-NME707>3.0.CO;2-9 ↗
22. Zlamal M (1980) Finite element method in physical and technical applications. Comput Phys Comm 20(1):37–4210.1016/0010-4655(80)90104-6 ↗
23. Ramadan M, Fourment L, Perchat E (2008) A Bimesh Method for Speeding-up Incremental Processes such as Cogging. Proceedings of the 9th International Conference on Technology of Plasticity (ICTP), Gyeongju, Korea
24. Ramadan M, Fourment L, Digonnet H (2009) A parallel two mesh method for speeding-up processes with localized deformations: application to cogging. Int J Mater Form 2(1):581–58410.1007/s12289-009-0440-x ↗
25. Ramadan M, Fourment L, Digonnet H (2009) Une méthode Bimaillages parallèle pour accélérer le temps de calcul des procédés incrémentaux. Acte du 9ème Colloque National en Calcul des Structures 1:999–104, Giens France
26. Ramadan M, Gavoille S, Fourment L, Digonnet H (2011) Une méthode MultiMaillages MultiPhysiques parallèle pour accélérer les calculs des procédés multiphysiques incrémentaux. Clé USB 10e colloque national en calcul des structures, Giens France
27. Coupez T (1994) A mesh improvement method for 3d automatic remeshing . In N P Weatherill et al. (Eds.), Numerical Grid Generation in Computational Fluid Dynamics and Related Fields, Pineridge Press, pp 615–626
28. Coupez T (2000) Génération de maillage et adaptation de maillage par optimisation locale. Revue européenne des éléments finis 9:403–42310.1080/12506559.2000.10511454 ↗
29. Alfaro I, Yvonnet J, Cueto E, Chinesta F, Doblare M (2006) Meshless methods with application to metal forming. Comput Meth Appl Mech Eng 195(48–49):6661–667510.1016/j.cma.2004.10.017 ↗
30. Alfaro I, Gonzalez D, Bel D, Cueto E, Doblare M, Chinesta F (2006) Recent advances in the meshless simulation of aluminium extrusion and other related forming processes. Arch Comput Meth Eng 13(1):3–4410.1007/BF02905930 ↗
31. Filice L, Alfaro I, Gagliardi F, Cueto E, Micari F, Chinesta F (2009) A preliminary comparison between finite element and meshless simulations of extrusion. J Mater Process Tech 209(6):3039–304910.1016/j.jmatprotec.2008.07.013 ↗