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Home  >  Journal list  >  MATERIALS TRANSACTIONS  >  Vol.49  No.2 (2008)  >  pp.278-283

MATERIALS TRANSACTIONS
<<Previous article Vol.49  No.2 (2008)   pp.278 - 283 Next article>>

Effect of Tool-Modeling Accuracy on Square-Cup Deep-Drawing Simulation

Takayuki Hama1), Masato Takamura2), Akitake Makinouchi3), Cristian Teodosiu3) and Hirohiko Takuda1)
1) Department of Energy Science and Technology, Kyoto University
2) Advanced Vehicle Manufacturing and Prototype Technology Department, Nissan Motor Co., Ltd.
3) Volume-CAD System Research Program, The Institute of Physical and Chemical Research


In this study, the effect of tool-modeling accuracy on a finite-element simulation of a square-cup deep-drawing process is examined. First, the accuracy of tool modeling using a conventional approach, in which polyhedral surfaces are used, is compared with that of an alternative approach, in which the quadratic parametric surfaces proposed by Nagata [Nagata, Comput. Aided Geom. D 22 (2005) 327–347] (Nagata patch) are used. It is clear that the Nagata patch yields a much more accurate tool geometry than the conventional approach with regard to the shape and normal vectors of the tool. Next, simulations of the square-cup deep-drawing process are carried out for die models with various numbers of tool elements. It was found that a polyhedral model with at least 10 divisions at the die shoulder is required to carry out accurate simulations. The simulated result of the Nagata patch model with two patches at the die shoulder corresponds well to that of the polyhedral model with more than 10 patches. From this point of view, it is concluded that the number of tool elements can be markedly decreased using the Nagata patch model. In the present case, the number of tool elements can be reduced to about 10% of that of the polyhedral model.


Keyword:
sheet metal forming, numerical analysis, tool-modeling accuracy, polyhedral approximation, quadratic polynomial patch, elastic-plastic finite-element method

Received: May 31, 2007
Accepted: October 27, 2007 , Published online: January 25, 2008
Copyright (c) 2008 The Japan Society for Technology of Plasticity

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