TY - JOUR

T1 - Development of a numerical compensation framework for geometrical deviations in bulk metal forming exploiting a surrogate model and computed compatible stresses

AU - Scandola, Lorenzo

AU - Büdenbender, Christoph

AU - Till, Michael

AU - Maier, Daniel

AU - Ott, Michael

AU - Behrens, Bernd-Arno

AU - Volk, Wolfram

N1 - Funding Information: The authors would like to thank the German Research Foundation (Deutsche Forschungsgemeinschaft, DFG) for financial support, provided under the grant numbers VO 1487/26 − 1. Open Access funding enabled and organized by Projekt DEAL.

PY - 2021/9

Y1 - 2021/9

N2 - The optimal design of the tools in bulk metal forming is a crucial task in the early design phase and greatly affects the final accuracy of the parts. The process of tool geometry assessment is resource- and time-consuming, as it consists of experience-based procedures. In this paper, a compensation method is developed with the aim to reduce geometrical deviations in hot forged parts. In order to simplify the transition process between the discrete finite-element (FE) mesh and the computer-aided-design (CAD) geometry, a strategy featuring an equivalent surrogate model is proposed. The deviations are evaluated on a reduced set of reference points on the nominal geometry and transferred to the FE nodes. The compensation approach represents a modification of the displacement-compatible spring-forward method (DC-SF), which consists of two elastic FE analyses. The compatible stress originating the deviations is estimated and subsequently applied to the original nominal geometry. After stress relaxation, an updated nominal geometry of the part is obtained, whose surfaces represent the compensated tools. The compensation method is verified by means of finite element simulations and the robustness of the algorithm is demonstrated with an additional test geometry. Finally, the compensation strategy is validated experimentally.

AB - The optimal design of the tools in bulk metal forming is a crucial task in the early design phase and greatly affects the final accuracy of the parts. The process of tool geometry assessment is resource- and time-consuming, as it consists of experience-based procedures. In this paper, a compensation method is developed with the aim to reduce geometrical deviations in hot forged parts. In order to simplify the transition process between the discrete finite-element (FE) mesh and the computer-aided-design (CAD) geometry, a strategy featuring an equivalent surrogate model is proposed. The deviations are evaluated on a reduced set of reference points on the nominal geometry and transferred to the FE nodes. The compensation approach represents a modification of the displacement-compatible spring-forward method (DC-SF), which consists of two elastic FE analyses. The compatible stress originating the deviations is estimated and subsequently applied to the original nominal geometry. After stress relaxation, an updated nominal geometry of the part is obtained, whose surfaces represent the compensated tools. The compensation method is verified by means of finite element simulations and the robustness of the algorithm is demonstrated with an additional test geometry. Finally, the compensation strategy is validated experimentally.

KW - Bulk metal forming

KW - Compatible stresses

KW - Compensation

KW - Geometrical deviations

KW - Surrogate model

KW - Tool design

UR - http://www.scopus.com/inward/record.url?scp=85101779716&partnerID=8YFLogxK

U2 - 10.1007/s12289-020-01603-7

DO - 10.1007/s12289-020-01603-7

M3 - Article

AN - SCOPUS:85101779716

VL - 14

SP - 901

EP - 916

JO - International Journal of Material Forming

JF - International Journal of Material Forming

SN - 1960-6206

IS - 5

ER -