Methods and systems for conducting a time-marching numerical simulation of a deep drawing metal forming process for manufacturing a product or part

Abstract

A FEA model representing a product/part with certain finite elements for metal portion, metal necking failure criteria (critical and fracture strain values defined in form of loading path diagram) and the neck's characteristics (neck's width and a profile of strain values within the width) are received in a computer system. At each solution cycle of a time-marching simulation of a deep draw metal forming process using the FEA model, following operations are performed at each integration point of every finite element: identifying major and minor strain values and corresponding directions from the computed strain values, calculating an equivalent metal necking failure strain value (ε) in the major strain direction with a formula based on corresponding critical and fracture strain values, the neck's characteristics and a characteristic dimension in the major strain direction, and determining metal necking failure, which occurs when the major strain value is greater than ε.