PROCEEDINGS OF

THE 8th ESAFORM CONFERENCE ON MATERIAL FORMING

,,ESAFORM 2005"

Volume I

Editor:

Prof. Dorel BANABIC

TIB/UB Hannover 89126 679 495

Contents

VOLUME I

PLENARY LECTURES

Plenary lecture Constitutive modeling for metals, 3F. Barlat

Plenary lecture Material forming and dimensioning problems: expectations from the car industry, 11G. Maeder

Plenary lecture Polymeric materials from fundamental research to specific applications, 21B.C. Simionescu, M. Pinteala, A. Stanciu, Gh. Fundueanu, V. Harabagiu

Identification of models and inverse analysis

FP033 Identification of the Parameters of a Damage Constitutive Law for Steel at Elevated 29

(Keynote paper) Temperature

S. Castagnc, A.M. Habraken

FP238 Optimization of Yield Criterion Descriptions using Genetic Algorithms 33(Keynote paper) B M c h a p a r r 0 > L F M e n c z e S ! j v Fernandes

FP055 Hybrid Modelling to Represent the Material Flow Stress Under Hot Deformation 37

Conditions

S. Bruschi, T.Dal Negro

FP067 Numerical Modeling of the Specimen Clamping System used in Shearing Tests 41

C. Maier, T. Yamada, M. Gaspcrini, V. Tabacaru

FP135 Determination of The Optimal Forging Conditions of A Cr-Mo-V High Alloy Steel 45

Through a Microstructural, Thermophysical and Mechanical Study

C. Bouffioux, M. Carton, J. Lecomtc-Beckers, A-M. Habraken

FP136 Material Parameters for Stamping Simulations Based on Tensile and Tension- 49

Compression Tests

M. Kraska, M. Herdy, J. Domhardt, K. Roll

FP227 Plasticity Parameters Identification for Steel Wires 53

T. Balan, R. Bigot, M.T. Pcrrot-Simonetta, M. Confentc

FP301 Inverse analysis using a genetic algorithm for FE Modellinf of Friction Stir Welding 57T. Dc Vuyst, L. D'Alvise, S. Picrret

FP054 Optimisation and Confidence Region Estimation of Constitutive Parameters in 61

Equations for Hot Metal Deformation

Mulyadi, M-A.Rist, L.Edwards and J.W.Brooks

FP078 Identification of Memory Kernels in Thermo-Viscoelasticity 65

M. Scllicr

III

ESAFORM2005 Conference, Cluj-Napoca, Romania

New and advanced numerical strategies in forming process simulation

FP188 State Of The Art And Recent Developments In The Numerical Modelling Of Metal 71

(Keynote paper) Forming Processes

J.-L. Chcnot

FP257 Possibilities of the Particle Finite Element Method in Casting Processes 77(Keynote paper) R ^ ^ R ^ ^ g R ^ ^ p ^ p j n

FP258 Remeshing Strategy for Damage Materials: A Transfer Operator based on Diffuse 81

(Keynote paper) Approximation

D. Branchcrie, P. Villon, A. Ibrahimbegovic, A. Rassmeux, P, Breitkopf

FP032 A Priori Model Reduction Method for Dynamical Problems Involving Impact and 85

Vibrations

D. Ryckclynck, F. Chinesta

FP090 Algorithmic Formulation and Numerical Implementation of Models for . 89Electromagnetic Metal FormingJ. Unger, M. Stiemcr, B. Svendsen, H. Blum

FP097 A Natural Neighbour Galerkin Method with Quadtree Structure 93

J. J. Laguardia, E. Cucto, M. Doblarc

FP110 Enriched Reproducing Kernel Particle Approximation for Simulating Problems 97

Involving Moving Interfaces: Application to Solidification Problems

J. Trunzler, P. Joyot,F. Chincsta, P. Reuter

FP117 Numerical Strategies for Describing Material Failure with Discrete Element Model 101

A. Dclaplacc, C. Rcy

FP142 Finite Element Analysis of Incremental Sheet Metal Forming 105

I. C.-O. Murcsan, A. Brosius, W. Hombcrg, M Kleiner

FP144 Modelling of Micro-Forming by Plasticity Gradient and Surface Layer Methods 109

N. Pcmin, J. Chambcrt. P. Picart

FP 170 A New Algorithm of Stamping Simulation of a Dual-Phase Steel Rail using Voxel 113ApproachM. Takamura, T. Hama, M. Banu, O. Naidim. K.. Kasc. C. Tcodosm, A. Makinouchi

FP212 Development of a Contact Model Adapted to Incremental Forming 117

C. Hcnrard, C. Bouffioux, A. Godinas, A.M. Habraken

FP234 Mesh Immersion Technique for Mo\ ing Domain Calculation. Application to Twin 121Screw Extrusion

R. Valctte, B, Hiroux, B. Vcrgnes, T. Coupcz

FP235 Stabilisation for Capturing Moving Surface and Incompressible Navier Stokes 125Solution

T. Coupcz, O. Basset, H . Digonnet

IV

Contents

FP248

FP096

FP119

FP122

FP247

FP296

A 3D Multidimensional VOF Advection Algorithm based on Edge-Matched Flux 129Polyhedrons

J. Lopez, J. Hernandez, F. Faura, P. Gomez,

Meshless Numerical Simulation of Laser Surface Coating Processes 133

D. Gonzalez, D. Bel, E. Cueto, M. Doblare, F. Chinesta, C.Lopez-Gascon, L. A. Angurel,G. F. de la Fuente

An Efficient Multiscale Parallel-ln-Time Strategy for Non-Linear Poro-Plastic 137

Problems

Ch. Rey, V. Chiaruttini

Numerical Simulation of Cold Roll Forming Process 141

Q.V. Bui, L. Papeleux, R. Boman, J.P. Ponthot, P. Wouters, R. Kergen, G. Daolio

Numerical and Experimental Study of Interface Dynamics and Air Entrapment in 145Diecasting Injection Chambers

R. Zamora, J. Hernandez, J. Lopez, F. Faura, P. Gomez

An Update on the 'State of the Art' in Forming, Heat Treatment and Machining 149Simulation

J. Walters, D. Lambert, R. Shankar, E. Reiss

Optimisation and stochastic approaches in the field of material forming

FP245 Metamodelling Techniques for the Optimisation of Metal Forming Processes 155(Keynote paper) M H A ^ ^ A H y a n d e n B o o g a a r <^ j Huetink

FP005 Optimisation of Process Parameters in Wiping Die Bending Operation in order to 159

Minimise of Stresses and Lemaitre's Damage

R. Bahloul, Ph. Dal Santo, A. Potiron

FP037 Gradient, Non-Gradient And Hybrid Algorithms For Optimizing 2D And 3D 163Forging SequencesL. Fourment, T.T. Do, A. Habbal, M. Bouzaiane

FP236 Optimizing the Post Sandvik Nanoflex Material Model using Inverse Optimization 167and the Finite Element MethodT. van Amstel, M. Groen, J. Post, J. Huetink

FP253 Identification of Material and Process Parameters in Sintering after Metal Injection 171Moulding

J. Song, G. Ayad, T. Barriere, J.C. Gelin, B. Liu, D. Renault

FP006 Application of Processing Path Model in Optimising Materials Forming 175

D.S. Li, J. Bouhattate, H. Garmestani

FP153 Numerical Modeling For Durability And Optimization Of Automotive Seat Back 179Frame

M. Bharatkumar, P. P. Date

ESAFORM 2005 Conference, Cluj-Napoca, Romania

Multiscale approach in material forming processes (micro-macro modelling)

FP223(Keynotepaper)

FP232(Keynote paper)

FPO49

FP105

FPI09

H'lb'4

FP220

FP225

FP228

FP239

FP275

FP285

FP168

Dislocation substructure and mechanical behaviour of metals 185

Micro-Macro Modelling of Permeability and Mechanical Dispersion in a Porous 189Medium

F. Loix, V. Thibaut. F Dupret

Two-Scale Approach to Dynamic Localization Failure of AISI 316H Stainless .93Steel Sheets

W. Gambin, K. Kowalczyk-Gajewska, L. T. Kudrjavceva, M. V. Micunovic

A Physically Based Micromechanical Approach to Model the Bake - Hardening 197Effect for Polycrystalline Low Carbon Steels

S. Berbenni, V. Favier, M. Berveiller, X. Lemoine

Constitutive Modelling of Damage Accumulation During the Hot Forming of Free- 201Cutting Steels

A. D. Foster, J. Lin. Y. Liu. D. Famipia, T. A. Dean

Welding of Thermoplastic Matrix Composites: Prediction ol Macromolecules' 205Diffusion at the Interface

G. Regnier, C. Nicodeau, J. Verdu, F. Chinesta, V.Triquenaux, J.Cinquin

A Numerical Study on the Onset of Plastic Instability in Extruded Materials with 209Strong Through-Thickness Texture Variation

S.K. Ijeldbo. B llolmedal. O.-G. Lademo. H. Bjeifcaas. S. Staren. H.J Roven, J. Hjelen,O.S. Hopperstad. T. Bcrstad. K.O. Pederscn. T. Furu

Dislocation-based intragranular hardening model taking into account strain path 213and strain rate changes for steels

A. Uenishi, C. Teodosiu, E. V. Nesterova

Effect of Temperature on Strength and Strain Hardening for Low Carbon Steel 217Deformed under Monotomc, Continuous and Reverse Loading

G. Vincze. E F. Rauch, J.J. Gracio. F. Barlat, A.li. Lopes

A Polycrystalline Model for Stress-Strain Behaviour of 316L Steel 221

S.Gallee, P.-Y.Manach, P.Pilvin. S.Thuillier, G.Lovato

On the Stress State Dependence of the TRIP-effect in Multiphase Steels 225

F. Lani, L. Delannay. Q. Furnemont. P. Jacques, T. Pardoen

A Phenomenological Parameter to Quantify the Efficiency of the Deformation 229Route for Grain Refinement

O. Bouaziz

Computing Model Regarding the Re-Crystallisation Activation Energy for the 233Warm Formed AISI 1015 Steel

C. Medrea - Bichtas

VI

Contents

FP226(Keynote paper)

FP031(Keynote paper)

FPO38(Keynote paper)

FP134(Keynote paper)

FP224(Keynote paper)

FP004

FP015

FP063

FP065

FP084

FP092

FP099

FP181

FP216

Sheet metal forming technologies and modeling

Some Basic Aspects of Constitutive Modelling in Sheet Metal Forming 239

C. Teodosiu

Three-Dimensional-Bending of Profiles by Stress Superposition 245

S. Chatti, M. Hermes, M. Kleiner

Optimisation of Specimen's Geometry for Characterisation of Plastic Yielding of 249Sheet Metal using a Novel Concept of Experimental Setup

M. Geiger, M. Merklein, W. Huflnatter

Development of a One-Point Quadrature EAS Solid-Shell Element for Sheet 253Forming Processes

R. J. Alves de Sousa, R. P.R. Cardoso, R. A. Fontes Valente, J.-W. Yoon, J. J. Gracio andR. M. Natal Jorge

Forming of Relief-Embossed Panels and Actual use in an Automotive Body 257

M. Gruenbaum, K. Roll, D. Lange

Numerical Analysis and Response Surface Method to Investigate Friction Effects 261in Sheet Bending Application

A. Mkaddem, R. Bahloul, A. Potiron

FEM-Simulation of Forming and Subsequently Impact Behaviour of a Stainless 265Steel Component

R.Andersson, C. Magnusson, J.Powell

Bending Limit and Characteristic on Off-Set Roller Bending 269

S.Kato, J.Endou

Friction Stir Welding and Cup Deep Drawing of Aluminium Tailored Blanks - 273Experiments and 3D-FE-Simulations

M. Merklein, A. Giera, D. Staud

A New Method to Realize the Multi-step Inverse Finite Element Analysis in Sheet 277Metal Stamping

Y. Huang, Y. P. Chen, R. Du

Determination of the Tensile Properties for the Welding Line of Tailored Welded 281Blanks

M. Tolazzi, M. Merklein

Overview and Introduction of Lightweight Engineering with Aluminum in cars 285

M. Vos

Development of Die-Embedded Micro Sensing System for Rending Process 289

M. Yang, J.-I. Koyama

Implementation and Comparison of Advanced Behaviour Laws for Sheet Metal 293Forming

G. Racz, X. Lemoine, B. Haddag, F. Abed-Meraim

VII

ESAFORM 2005 Conference, Cluj-Napoca, Romania

FP237

FP264

FP265

FP272

FP297

FP053

FP128

FP152

FP177

FP182

Numerical simulation of Multi-Step Decp-Drawing Processes 297

A.J. Baptista, J.L. Alves, M.C. Oliveira, D.M. Rudrigucs. L.F. Mcnczcs

Virtual Approval of Forming Dies 301

M. Zicglcr, D. Meyer, A. Rennet

Modelling of Precipitation Hardening and Mechanical Properties of Creep Age- 305Formed Parts

J. Lin, K. C. Ho and T. A. Dean

FEM Analysis in Die Design Practice 309

M. Tisza, Z. Lukacs, M. Tisza jr.

Localised Bending Defects in Circular Tube Roll-Forming 313

M. Salmani Tehrani, P. Hartley, H. Moslemi Nacini. M. Farzin

Experimental Research for Determining the Forces on Incremental Sheet Forming 317Process

O. Bologa, V. Oleksik, G. Racz

Sheet Metal Forming Simulation using EAS-Based Solid-Shell Finite Elements 321

M. P. L. Parcntc, R. A. Fontos Valcnte, R. M. Natal Jorge. R. P R. Cardoso, R. J. Alvcsdc Sousa

Study of Various Initial Blank Shapes to Minimize the Earing in the Octagonal 325Shaped Multistage-Formed Part using Finite Element Analysis

Sharvari G. Desai, R. H. Pardeshi, P.P.Date

A Deep Drawing Test Used to Evaluate the Performances of Different Yield 329Criteria

G. Cosovici, D. Baiiabic

Virtual Deep Drawing Process with Combined Restraint

V. Paunoiu, D. Nicoara, C. Spiridonescu, A. Epureanu

333

FP200(Keynote paper)

FP086(Keynote paper)

FP242(Keynote paper)

FP283(Keynote paper)

Anisotropy and formability of materials

Anisotropy And Formability In Sheet Metal Drawing 339

P. Van Houtlc

Flash Design of Optimum Blanks for Deep Cups Drawn From Anisotropic Sheets 343

K. Isobc

Prediction of Plastic Instability and Fracture in Extruded Aluminium Alloys in 347Shell Element Analyses

O.-G. Lademo,O.S. Hopperstad,T. Berstad, M. Langscth

Anisotropic Elasto-plastic Model for Large Metal Forming Deformation Processes 351

S. Clcja-Tigoiu

VIII

Contents

FP016 Numerical Analysis of the Effects of the Martensitic Phase Transformation on the 355Formability of Unstable Austenitic Steels

J. Serri, M. Martiny, G. Fcrron

FPO19 Formability Behaviour of Meta-Stable Stainless Steels 359

R.Andcrsson, M.Syk, C. Magnusson, J.Powell

FP066 Experimental Validation of Damage Parameters by using Vickers Micro Hardness 363

Technique

F. Gassara, A. Mkaddem, R. Hambli

FP091 Effect of Anisotropic Yield Function on Sheet Forming Simulation of Miniature 367

Fender Model for Aluminum Alloys

K. Yamada, M. Asano, H. Mizukoshi, K. Okada

FP103 Behaviour of Extruded Aluminium Alloy Sheets under Non-Proportional Loading 371

D.Achani, O.S. Hopperstad, O-G. Ladcmo

FP111 A Critical Review of the Forming Limit Stress Curve Approach for Judging 375

Forming Severity in Deep Drawing Processes

A. Ofenheimcr, B. Buchmayr, H. Ccrjak

FP126 Orthotropic Yield Criterion for Mg Alloy Sheets 379

O. Cazacu, B. Plunkctt, F. Barlat

FP127 Evaluation of Stresses in a Combined Plane Strain - Simple Shear Test 383

A.H. van den Boogaard. M. van Ricl, J. Huetink

FP143 Validation of the Non-Linear Strain Path Model CRACH to Enhance the 387

Interpretation of FE-Simulations in Multistage Forming Operations

G. Rajarajan, M. Kleiner, H. Roesen, L. Kessler

FP151 Application of the YLD96 Yield Criterion on Describing the Anisotropy and 391

Formability of BCC Materials

M.C. Buhic, J.J. Gracio and A. Barata da Rocha

FP156 Modeling the Influence of Strain on the Yield Surface of Magnesium 395

X. Ma, M.R. Barnett, C.H.J. Davies

FP158 Forming Limits of 5000 Series Aluminum Alloys with Different Magnesium 399

Contents

T. Kuwabara, M. Umemura, K. Yoshida, K. Kuroda, S. Hirano

FP183 Mechanical Properties and Dislocation Substructure Evolution in Cu Added 403

Ferritic Steel

G. Shigesato, E.F. Rauch

FP244 Effects of Strain and Strain Path on the Developments of Crystallographic Texture 407

and Microtexture of a Commercial Purity Aluminum

M. Dccpa, R. Banchhor, I. Samajdar, K. Narasimhan

FP271 Finite-Element Predictions of Earing using recent 3-D yield criteria for aluminum 411

S. Soare, J.-W. Yoon, F. Barlat, O. Cazacu

IX

ESAFORM 2005 Conference, Cluj-Napoca, Romania

FP116 Anisotropic Strain Rate Potential for Aluminum Alloy Plasticity 415

F. Barlat, K. Chung

FP175 Calculation ofForming Limit Diagrams Using a Finite Element Model 419

L. Paraianu, D. Banabic

FP176 A User-Frienldy Programme for Calculating Forming Limit Diagrams 423

P. Jurco, D. Banabic

FP 178 Theoretical Models for the Determination of Forming Limit Diagrams 427

D. Banabic, H. Arete, L. Paraianu, P. Jurco, M. Vds .

FP201 Description of the Anisotropic Yield Behaviour of Aluminium Alloy Sheets using 431

Phenomenological and Texture Based Yield Criteria

D. Banabic, S. Li, A. Van Bael, P. Van Houttc

FP270-partI Effect of weld conditions on the forming limit strains of Tailor Welded Blanks 435

R. Ganesh Narayanan, K. Narasimhan

FP270 - part II Effect of weld conditions on the forming limit strains of Tailor Welded Blanks 439

R. Ganesh Narayanan, K. Narasimhan

Hydroforming of sheet metals and tubes

FP259 Recent advances in process design for sheet and tube hydroforming 445(Keynotepaper) j . c . G e l in, C. Labcrgere

FP018 Design of a Modular System for Tube Hydroforming for Realizing a Motorbike 451Suspension Component

C.Giardini, E. Ccrctti, C. Contri

FP073 Improvement of Axial Sliding in the Tube Hydroforming Process of Long 455

Components due the Reduction of Friction by High Viscous Fluid Flow

M. Geigcr, P. Dal B6

FP141 Residual Stress Distribution in the Workpiece Bottom in High-Pressure Sheet 459

Metal Forming

R. Krux, W. Hombcrg, M. Kleiner

FP210 Hydroforming of Tailor-Welded Tubular Blanks 463

A.P. Roque, R.M. Natal Jorge, M.PX. Parente, R.A.F. Valente, A.A. Fcrnandes

FP218 Finite Element Study of the Manufacturing of Joint Bellows by Hydroforming 467

Processes

M. Estrcms, R. Fernandez, P. Franco

FP246 Combination of Deep Drawing with Subsequent Hydroforming 471

S. Wagner, S. JSger, S. Rudolf

FP260 Hydroforming of Metallic Liners for High Pressure Hydrogen Storage 475

C. Labcrgere, J.C. Gelin, N. Boudcau, M. Batiat, S. Thibaud

X

Contents

FP219

(Keynote paper)

FP042

FP171

FP298

FP280

FP165(Keynote paper)

FP290(Keynote paper)

FP002

FP064

FP163

FP273

FP284

FP022

FPO83

Springback in sheet metal forming

Sheet Springback: Prediction and Design 481

R. H. Wagoner, M. Li, J. F.Wang

Simulation of Secondary Operations and Springback - The Implicit Shell Provides 485a Precise and Rapid Solution

E. Schonbach, G. Glanzer, W. Kubli, M. Selig

Influence of the Kinematic Hardening on the Springback Prediction of High 489Strength Steels in the Draw Bending Test

M. Banu, S. Bouvier, C. Teodosiu, V. Tabacaru, V. Marinescu

Research of Springback Behavior in Sheet Metal Bending and the Factors 493Influencing Springback

P. Sun, J.A. Ferreira, J.J. Gracio

Springback Reduction for V Bended Parts through Elastic Pads 497

L. Hancu, Gh. Achimas

Forging technologies and modelling

Evaluating The Press Stiffness In Realistic Operating Conditions 503

A. Ghiotti, P. F. Bariani

An Adaptive Finite Element Strategy for Fracture Analysis in Visco-plastic Solid 507

F.M. Andrade Pires, E.A. de Souza Neto, D.R.J. Owen, J.M. Cesar de Sa

Experimental and Numerical Investigation of Friction in Hot Isothermal 511Deformation of Aluminium Alloy AA30O3

P. A. Petrov, M. A. Petrov

Microstructure Simulation in Radial Forging of Nickel Base Alloys 515

O. Harrer, C. Sommitsch, S. Wallner, V. Wieser

Use Of Concealed Pressure Pins To Determine Contact Stresses In Ring 519Compression

R. Lupoi, F.H. Osman

Analysis And Experimental Verification Of Cold Cylinder Upsetting By Spherical 523Dies

D. Vilotic, M. Plancak, V. Mandic, D. Cupkovic

Formability Maps in Cold Forging with Conical Dies 527

P. Hartley, D. Vilotic, M. Plancak

Calculation of the Material Flow Ratio Beneath the Roller in the Axial and the 531Circumferential Directions During Flow-Forming Process by Simulation

M.H.Parsa, A.M.A.Pazooki

Forging Preform Design Using Ideal Forming Theory 535

M.H.Parsa, M. Ghadamgahi-Kashan, M. Hashemi

XI