Finite Element Modeling of Tube Piercing and Creation of a Crack

Abstract : A 3D simulation of Mannesmann tube piercing is performed using the finite element software Forge 2005®. The sensitivity of the simulation results to numerical methods and physical parameters is discussed. Advanced numerical schemes and refined time discretizations are required to obtain correct descriptions of the material flow. In this study, one concentrates on the stress state and damage development before the material comes in contact with the plug. Indeed, the crack is to appear prior to the action of the plug. The description of the material behaviour is found to be a key information to predict the crack development. Predictions based on a modified Lemaitre damage law and a normalised Latham and Cockroft criterion are compared.