Product shape change by internal stresses. (5th November 2018) - Groen, M.
Abstract: The design of a product component may require complex processing steps such as metal forming followed by a thermal treatment. The thermal treatment may improve the functional performance of the material itself, but may result in rather unwanted changes in the shape of the product. Here it is shown that Finite Element modeling of the various processes can assist in the design of a robust and accurate production process. The modeling approach presented allows a coupling between various complex material models, in such a way that full cold forming and thermal treatment processes are calculated. This coupling of material models is key for the design and concerns the novelty of the proposed approach. Cold forming by deep drawing is calculated whereby planar anisotropy is implemented. The thermal hardening treatment consists of three contributions: creep, thermal expansion and phase transformation. All models are based on experimental data, acquired from tensile and dilatometer tests, and are implemented into the material model either directly or by a simple fit. It is shown that the effects of a complete forming and heat treatment of a cup could be successfully calculated. The predicted cup shape change was compared to experiments, and shows excellent agreement. Graphical abstract: Unlabelled Image Highlights: The predictability and accuracy of the shape changes in the product design Coupling between forming and thermal treatment Processing steps of forming and thermal treatment are successfully implemented in the Finite Element computer code.