Simulation of a high-speed forming

adiabatic transformation

Adiabatic forming plays a crucial role in high-speed forming processes involving materials with special properties. An example of the application of adiabatic forming is the cold forming of high-strength steels. These steels have high strength and low ductility, but can be processed at high speeds by adiabatic forming. This increases their elasticity, and complex components can be manufactured.
Another example is the forming of aluminum alloys. Aluminum has a high thermal conductivity, which means that it can cool down quickly during the forming process. Adiabatic forming allows the material to be deformed quickly and efficiently, reducing the occurrence of cracks and defects.
Magnesium alloys are also advantageously processed by adiabatic forming. Magnesium alloys are light but brittle. By using adiabatic forming, these alloys can be formed more quickly and with less risk of cracking.

Material and FEM simulation

Various aspects must be taken into account when calculating the adiabatic transformation. The frictional heat generated during the forming process has a significant impact on the temperature distribution in the material and the deformation behavior. The calculation of the frictional heat is based on empirical data and experimental investigations.
The material behavior also plays an important role. Accurate modeling of material behavior in terms of hardening and deformability is crucial. Material models such as the Johnson-Cook model or the Zerilli-Armstrong model are often used to describe the behavior of the material under high strain rates.
Finite element simulation is a widely used tool to analyze and predict adiabatic forming. The forming conditions, the material model and the friction conditions are integrated into the simulation to predict the temperature distribution, stresses, deformations and potential defects.
Stress-strain curves, hardening curves and damage curves are typically required to determine the material characteristics for adiabatic forming. These are derived from experimental data, usually obtained by testing in tension or compression at various strain rates and temperatures.
Calculating the adiabatic strain requires a comprehensive approach based on a combination of experimental data, material modeling and numerical simulations. When carried out by IngTechAS, you will receive all the calculation bases and have access to the most modern software solutions for sheet metal forming!

Procedure for a simulation:

In order to perform an adiabatic forming simulation, we are required to follow several steps. Here are the basic steps for such a simulation:

1. 1. Problem statement: We clearly define the problem and set our goals for the simulation. We identify the part to be formed, the forming conditions and the specific aspects we want to study, such as temperature distribution, stresses, deformations or potential defects.
   2. Geometry modeling: We create a three-dimensional model of the component that contains the forming geometry and the material dimensions. We use different CAD software and respond to your wishes.
   3. Mesh Generation: The geometry model is subdivided into a mesh of finite elements. This mesh allows us to discretize the part and simulate the behavior of the material. We choose the size and shape of the elements in such a way that we achieve an accurate prediction of the deformation behavior. Mesh generation is typically done using finite element simulation software.
   4. Material modelling: We choose a suitable material model to describe the behavior of the material during adiabatic deformation. The material model adequately accounts for the specific properties of the material, such as elasticity, plasticity, hardening, and damage. We determine the required material characteristics, such as stress-strain curves, hardening curves and damage curves, based on experimental data.
   5. Boundary Conditions: We set the boundary conditions for the simulation to simulate the forming conditions. These include the speed of the tool, the coefficients of friction, the forming temperature and the forming speed. We choose these parameters based on the real forming conditions or experimental data.
   6. Definition of the analysis parameters: We determine the desired analysis parameters, such as temperature distribution, stresses, deformations or potential defects. We determine which information should be extracted from the simulation and analyzed.
   7. Carrying out the simulation: We carry out the simulation using the selected finite element simulation software STampackXpress. We use the defined boundary conditions, material models and analysis parameters. We start the simulation and repeat the process until a stable state is reached.
   8. Analysis of results: We analyze the results of the simulation. We look at the temperature distribution, stresses, deformations and potential defects in the component. We compare the simulation results with experimental data to verify the accuracy and reliability of the simulation.
   9. Validation: We validate the simulation results against experimental data to ensure that the predictions