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Webinar: NAFEMS Contact Benchmark 3: Sheet Metal Forming
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2 Geometries 2 Meshes 1 Simulation setup 1 ResultAbout this project
Project Description: Sheet Metal Forming Simulation This SimScale project simulates a highly nonlinear sheet metal forming process using a punch, a die (both steel), and a sheet metal part (aluminum). Goals: Determine the final part shape and measure the reaction force, comparing it to NAFEMS benchmark data. Setup Details: Analysis: Nonlinear mechanical analysis (Marc) Geometry: A quarter symmetry model was created using two split operations to save time. Materials: Standard steel for tools; an elastoplastic material model with a multilinear curve specification for aluminum. Mesh: Second-order quad-dominant elements, generated using extrusion mesh refinement, suitable for bending. Contact: Contact was defined between the three parts, specifying the NAFEMS standard friction coefficient. Load Steps: Solved in three steps: tool positioning, punching (28.5 mm displacement per NAFEMS), and retraction. BCs: Imposed displacement was used for die fixing and punch movement/retraction. Stabilization (fixing all degrees of freedom) was applied to the sheet metal during positioning to prevent free movement. Imposed displacement was used on the cut faces for quarter symmetry. Results: Extra results requested include equivalent plastic strain and contact pressure. The total reaction force was calculated on the moving surface of the punch. The final calculated force must be multiplied by four due to the quarter symmetry. The results closely match the NAFEMS benchmark, predicting the peak force accurately and following the trend.
