Finite element simulation of forming, joining and strength of sheet components

Abstract : A 3-D solid finite element simulation of sheet forming processes is briefly discussed. Examples of cold or warm deep-drawing and sheet hydro forming are presented. Sheet work-pieces can be assembled to produce complex components by using different techniques: such as welding or mechanical fastening. They must also be simulated in order to evaluate and optimise the quality of the parts; examples of hemming and of self piercing riveting are described. Structural computation allows us to evaluate the strength of a component and especially the strength of the joining. In the future, more precise optimization of the components will be possible by the transfer of data from the previous stages of sheet forming and joining, to the structural computation code. This input data will be firstly the distribution of residual stresses, the evolution of local properties such as elastic limit, damage and anisotropy. An example of structural computation on a system of two sheets assembled by a single rivet is presented.