The light weight of parts manufacturing in the automotive, aerospace and aerospace industries has led to the prediction of wrinkling instability defects in sheet metal forming, which has become a major concern of the industry. However, based on the current status of conventional numerical simulation algorithms that do not include wrinkle instability criteria and thereout cannot implement the wrinkle numerical predictions, the plate diagonal tensile testing is used as a comparative verification object to find the proper numerical prediction methods for wrinkling instability. With the platform software ABAQUS it is confirmed that the conventional shell element dynamic algorithm (*DYNAMIC) used to simulate the deformation of thin-walled parts and the arc length method (*RIKS) used for structural part buckling calculation cannot be used to calculate the wrinkle problem of sheet metal forming. Three ways of sheet wrinkling instability prediction method:"the eigenvalue analysis(* BUCKLE analysis) for microdefects introduction + *DYNAMIC analysis", "*BUCKLE analysis + *RIKS analysis" and "three-dimensional solid element dynamic display algorithm" are tried and compared with the tests. The three algorithms are studied in terms of calculation accuracy, application scope, and algorithm features. The numerical simulation method with the best comprehensive performance for solving the wrinkling instability problem in sheet metal forming is established.
DU Bing
,
GUAN Fenglong
,
SONG Pengfei
,
HAN Zhaojian
,
ZHANG Xin
,
ZHAO Changcai
. Numerical Simulation Methods of Sheet Metal Wrinkling Instability Problem[J]. Journal of Mechanical Engineering, 2018
, 54(24)
: 42
-50
.
DOI: 10.3901/JME.2018.24.042
[1] 陈一哲,刘伟,苑世剑. 薄板液压成形起皱预测及控制研究进展[J]. 机械工程学报, 2016, 52(4):20-28. CHEN Yizhe, LIU Wei, YUAN Shijian. Research development on wrinkling predicition and suppression for sheet hydroforming of thin-walled deep drawing parts[J]. Journal of Mechanical Engineering, 2016, 52(4):20-28.
[2] LIU N, YANG H, Li H, et al. A hybrid method for accurate prediction of multiple instability modes in in-plane roll-bending of strip[J]. Journal of Materials Processing Tech, 2014, 214(6):1173-1189.
[3] WANG X, LEE L H N. Postbifurcation behavior of wrinkles in square metal sheets under Yoshida Test[J]. International Journal of Plasticity, 1993, 9(1):1-19.
[4] KIM J, YANG D, YOON J, et al. The effect of plastic anisotropy on compressive instability in sheet metal forming[J]. International Journal of Plasticity, 2000, 16(6):649~676.
[5] KIM J B, YOON J W, YANG D Y. Investigation into the wrinkling behaviour of thin sheets in the cylindrical cup deep drawing process using bifurcation theory[J]. International Journal for Numerical Methods in Engineering, 2003, 56(12):1673-1705.
[6] KIM J B, YOON J W, YANG D Y. Wrinkling initiation and growth in modified Yoshida buckling test:Finite element analysis and experimental comparison[J]. International Journal of Mechanical Sciences, 2000, 42(9):1683-1714.
[7] KIM J B, YANG D Y, YOON J W. Bifurcation instability of sheet metal during spring-back[J]. Philosophical Magazine, 2013, 93(15):1914-1935.
[8] RUST W, SCHWEIZERHOF K. Finite element limit load analysis of thin-walled structures by ANSYS (implicit), LS-DYNA (explicit) and in combination[J]. Thin-Walled Structures, 2008, 41(2):227~244.
[9] WONG W, PELLEGRINO S. Wrinkled membranes Ⅲ:numerical simulations[J]. Journal of Mechanics of Materials and Structures, 2006, 1(1):63-95.
[10] WONG W, PELLEGRINO S. Wrinkled membranes I:experiments[J]. Journal of Mechanics of Materials and Structures. 2006, 1(1):3-25.
[11] 刘腾喜. 正交各向异性金属板料成形的力学分析[D]. 杭州:浙江大学, 2001. LIU Tengxi. Mechanical analysis of orthotropic metal sheet forming[D]. Hangzhou:Zhejiang University, 2001.
[12] 陈奇广. 圆锥形件拉深成形侧壁起皱预测[D]. 湘潭:湘潭大学, 2015. CHEN Guangqi. Prediction of wall wrinkling in deep drawing of conical parts[D]. Xiangtan:Xiangtan University, 2015.
[13] ANARESTANI S S, MOROWATI M R, VAGHASLOO Y A. Influence of anisotropy and lubrication on wrinkling of circular plates using bifurcation theory[J]. International Journal of Material Forming, 2014, 8(3):1-16.
[14] SHAFAAT M A, ABBASI M, KETABCHI M. Investigation into wall wrinkling in deep drawing process of conical cups[J]. Journal of Materials Processing Tech, 2011, 211(11):1783-1795.
[15] CAO J, BOYCE M C. Wrinkling behavior of rectangular plates under lateral constraint[J]. International Journal of Solids & Structures, 1997, 34(2):153-176.
[16] CAO J. Prediction of plastic wrinkling using the energy method[J]. Journal of Applied Mechanics, 1999, 66(3):646.
[17] WANG X, CAO J. An analytical prediction of flange wrinkling in sheet metal forming[J]. Journal of Manufacturing Processes, 2000, 2(2):100-107.
[18] WANG X, CAO J. On the prediction of side-wall wrinkling in sheet metal forming processes[J]. International Journal of Mechanical Sciences, 2000, 42(12):2369-2394.
[19] 王耀,郎利辉,孔德帅,等. 铝合金覆层板成形极限图[J]. 中南大学学报(自然科学版), 2017, 48(5):1149-1154. WANG Yao, LANG Lihui, KONG Deshuai, et al. FLDs of aluminum alloy by overlapping sheet metal[J]. Journal of Central South University, 2017, 48(5):1149-1154.
[20] 李翠玉,张义同,张小涛. 基于MSC.Marc接口的机织物悬垂屈曲数值模拟[J]. 机械工程学报, 2008, 44(4):165-170. LI Cuiyu, ZHANG Yitong, ZHANG Xiaotao. Numerical simulation of draping and buckling of woven fabric based on MSC.Marc interface[J]. Journal of Mechanical Engineering, 2008, 44(4):165-170.
[21] 王殿龙,骆广,王欣,等. 基于弧长法的桁架臂结构全过程非线性稳定性分析[J]. 中国工程机械学报, 2015, 13(6):480-485. WANG Dianlong, LUO Guang, WANG Xin, et al. Full-process nonlinear stability analysis on truss booms via arc-length method[J]. Chinese Journal of Construction Machinery, 2015, 13(6):480-485.
[22] PAPADOPOULOS V,PAPADRAKAKIS M. The effect of material and thickness variability on the buckling load of shells with random initial imperfections[J]. Computer Methods in Applied Mechanics & Engineering, 2005, 194(12-16):1405-1426
[23] PAQUETTE J A, KYRIAKIDES S. Plastic buckling of tubes under axial compression and internal pressure[J]. International Journal of Mechanical Sciences, 2006, 48(8):855-867.
[24] 庄茁. 基于ABAQUS的有限元分析和应用[M]. 北京:清华大学出版社, 2009. ZHUANG Zhuo. Finite element analysis and application based on ABAQUS[M]. Beijing:Tsinghua University Press, 1986.
