Materials Processing and Design

MATERIALS PROCESSING AND DESIGN

Modeling, Simulation and Applications

NUMIFORM '07

Proceedings of the 9th International Conference on Numerical Methods in Industrial Forming Processes

Porto, Portugal 17 – 21 June 2007

PAR T I

EDITORS J. M. A. César de Sá Abel D. Santos Faculty of Engineering, University of Porto Porto, Portugal

All papers have been peer reviewed.

SPONSORING ORGANIZATIONS Faculty of Engineering of the University of Porto (FEUP) Institute of Mechanical Engineering and Industrial Management (INEGI)

Melville, New York, 2007 AIP CONFERENCE PROCEEDINGS VOLUME 908 Editors

J. M. A. César de Sá Abel D. Santos

Department of Mechanical Engineering and Industrial Management Faculty of Engineering of the University of Porto Rua Dr. Roberto Frias 4150-746 Porto Portugal E-mail: [email protected] [email protected]

The articles on pp. 301 – 306, 313 – 318, 331 – 336, 787 – 792, and 793 – 798 were prepared on behalf of the National Research Council, Canada, and therefore the copyright in these papers belongs to the Crown in Right of Canada, i.e., to the Government of Canada.

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L.C. Catalog Card No. 2007925727 ISBN 978-0-7354-0415-1 (Original Print) ISSN 0094-243X

Printed in the United States of America CONTENTS Preface ...... xix Organization ...... xxi

PART I PLENARY LECTURES

Constitutive Descriptions for Metal Forming Simulations...... 3 F. Barlat Three-dimensional Modeling of Void Growth in Friction Stir Welding of Stainless Steel ...... 25 Y. He, D. E. Boyce, and P. R. Dawson Computational Modelling of a Thermoforming Process for Thermoplastic Starch ...... 35 D. Szegda, J. Song, M. K. Warby, and J. R. Whiteman Computational Strategies for Polymer Coated Steel Sheet Forming Simulations ...... 49 D. R. J. Owen, F. M. Andrade Pires, and M. Dutko Convection of Local Level Set Function for Moving Surfaces and Interfaces in Forming Flow ...... 61 T. Coupez The Role of a General Purpose Code in Forming Simulations ...... 67 N. Rebelo, J. Nagtegaal, D. Fox, S. Sinha, and J. Brouwer

MINI SYMPOSIA Prediction of Necking and Fracture in Metal Sheets In memory of Prof. Alf Samuelsson Organized by: K. Mattiasson

Predictions of Necking with Analytical Criteria and Comparisons with Experimental Results...... 81 M. Brunet and P. Clerc Influence of the Plastic Material Behaviour on the Prediction of Forming Limits ...... 87 H. Vegter, C. H. L. J. ten Horn, and A. H. van den Boogaard On Necking, Fracture and Localization of Plastic Flow in Austenitic Stainless Steel Sheets ...... 93 A. S. Korhonen, T. Manninen, and K. Kanervo Possibilities and Influencing Parameters for the Early Detection of Sheet Metal Failure in Press Shop Operations ...... 99 J. Gerlach, L. Kessler, U. Paul, and H. Ro¨sen Damage Prediction in Sheet Metal Forming ...... 105 K. Saanouni and H. Badreddine Modelling of Local Necking and Fracture in Aluminium Alloys...... 111 D. Achani, M. Eriksson, O. S. Hopperstad, and O.-G. Lademo Formability Prediction of Aluminum Sheet in Automotive Applications ...... 117 C. Leppin, D. Daniel, R. Shahani, H. Gese, and H. Dell SEM-EBSD Based Realistic Modeling and Crystallographic Homogenization FE Analyses of LDH Formability Tests ...... 123 H. Kuramae, N. Ngoc Tam, Y. Nakamura, H. Sakamoto, H. Morimoto, and E. Nakamachi On the Prediction of Plastic Instability in Metal Sheets ...... 129 K. Mattiasson, M. Sigvant, and M. Larsson Prediction of Ductile Failure in the Stretch-Forming of AA2024 Sheets ...... 135 C. Vallellano, C. Guzmań, and F. J. Garcıá-Lomas Forming Limit Predictions for the Serrated Strain Paths in Single Point Incremental Sheet Forming...... 141 P. Eyckens, S. He, A. Van Bael, P. Van Houtte, and J. Duflou About the Neglected Influence of Gradients on Strain Localisation...... 147 A. Col and T. Balan Prediction of Formability in Sheet Metal Forming Processes Using a Local Damage Model...... 153 P. Teixeira, A. D. Santos, J. Ce´sar de Sa´, F. Andrade Pires, and A. Barata da Rocha

v Anisotropy and Formability in Sheet Metal Forming ...... 159 P. Van Houtte, A. Van Bael, and S. He CrachFEM—A Comprehensive Approach for the Prediction of Sheet Metal Failure ...... 165 H. Dell, H. Gese, and G. Oberhofer Increasing the Robustness of the Sheet Metal Forming Simulation by the Prediction of the Forming Limit Band ...... 171 D. Banabic, M. Vos, L. Paraianu, and P. Jurco

Recent Developments in Forming Processes On the occasion of the 60th anniversary of Prof. Jean-Loup Chenot Organized by: Lionel Fourment, Thierry Coupez and Francisco Chinesta

A General Arbitrary Lagrangian Eulerian Formulation for the Numerical Simulation of 3D Forming Processes ...... 179 R. Boman, L. Papeleux, and J. P. Ponthot Error Estimation and Accurate Mapping Based ALE Formulation for 3D Simulation of Friction Stir Welding...... 185 S. Guerdoux and L. Fourment Numerical Modelling of Metal Flow in the Cold Forming of Industrial Fasteners ...... 191 P. Hartley Finite Element Simulation of Plastic Joining Processes of Steel and Aluminum Alloy Sheets ...... 197 K. Mori, Y. Abe, and T. Kato Meshless Simulation of Friction Stir Welding ...... 203 I. Alfaro, L. Fratini, E. Cueto, F. Chinesta, and F. Micari From Steady-State to Cyclic Metal Forming Processes ...... 209 P. Montmitonnet Development of Multi-Scale Finite Element Analysis Codes for High Formability Sheet Metal Generation...... 215 E. Nakamachi, H. Kuramae, N. Ngoc Tam, Y. Nakamura, H. Sakamoto, and H. Morimoto Multi Scale Modeling of Phenomena Caused by Changes of the Deformation Path in Materials Forming...... 221 L. Madej, P. D. Hodgson, and M. Pietrzyk Finite Element Prediction of Sheet Forming Defects Using Elastic-Plastic, Damage and Localization Models...... 227 B. Haddag, F. Abed-Meraim, and T. Balan Anisotropic Volume Mesh Generation Controlled by Adaptive Metric Space ...... 233 B. Głut, T. Jurczyk, and J. Kitowski Improved Contact Algorithms for Implicit FE Simulation of Sheet Forming...... 239 S. Zhuang, M. G. Lee, Y. T. Keum, and R. H. Wagoner Failure Prediction in Forming Processes ...... 245 J. M. A. Ce´sar de Sa´ and C. Zheng Milling Process FEM Simulation for Identiﬁcation of Material Parameters Directly from Experiments ...... 251 A. Maurel, M. Fontaine, S. Thibaud, G. Michel, and J. C. Gelin 3D FEM Simulation of the Flow Forming Process Using Lagrangian and ALE Methods ...... 257 M. Houillon, E. Massoni, E. Ramel, and R. Loge´ Optimum Structural Topology and Shape Design Using Three Phase Hybrid GA and Artiﬁcial Density Method ...... 263 C. V. Ramakrishnan, N. Singh, and D. K. Sehgal Cimlib: A Fully Parallel Application for Numerical Simulations Based on Components Assembly ...... 269 H. Digonnet, L. Silva, and T. Coupez Design Optimization for Three-dimensional Extrusion Processes...... 275 D.-Y. Yang, S.-R. Lee, and K.-J. Kim Numerical Forming Simulations and Optimisation in Advanced Materials ...... 281 J. Hue´tink, A. H. van den Boogaard, H. J. M. Geijselears, and T. Meinders

vi Numerical Simulation of Polymer Processing Organized by: Thierry Coupez, L. Silva and Jean-Franc¸ois He´tu

Advanced Multiscale Modelling of Composite Welding Processes ...... 289 F. Chinesta, A. Ammar, F. Lemarchand, P. Beauchene, and F. Boust Integrated Simulation of an Aspheric Lens Combining Injection Moulding Analysis with Ray Tracing...... 295 K. Park and W. Joo Three-dimensional Numerical Simulation of Segregation in Dense Suspensions ...... 301 F. Ilinca and J.-F. He´tu A New Approach for the Validation of Filling Simulations in Micro Injection Moulding...... 307 A. Gava, G. Tosello, H. N. Hansen, M. Salvador, and G. Lucchetta Numerical Simulation of the Flow Behavior and Breakthrough Phenomenon in Co-injection Molding ...... 313 F. Ilinca and J.-F. He´tu Fluid Structure Interaction Techniques for Extrusion and Mixing Processes...... 319 R. Valette, B. Vergnes, and T. Coupez An Accurate Simulation of Thermoforming and Blow-molding Processes Using the Space Fiber Rotation „SFR… Concept ...... 325 T. Ghomari, R. Ayad, and N. Talbi The Use of Elasto-visco-plastic Material Model Coupled with Pressure-volume Thermodynamic Relationship to Simulate the Stretch Blow Molding of Polyethylene Terephthalate ...... 331 H. Mir, Z. Benrabah, and F. Thibault Simulation of the Cooling of a Semi-Crystalline Polymer in the Injection Molding Process Including PVT Behavior ...... 337 N. Brahmia, M. Zinet, M. Boutaous, P. Chantrenne, P. Bourgin, and D. Garcia Rheology of Suspensions Derived from Numerical Simulation ...... 343 M. Ahamadi and O. G. Harlen Numerical Modeling of the Deformation in Polymer Blends under Shear Flow ...... 349 A. Shahshahani, S. Dufour, and M.-C. Heuzey Injection Molding Simulation: Taking into Account the Process History to Predict the Anisotropy in the End-use Properties ...... 355 L. Silva, H. Miled, P. Laure, and T. Coupez Two-Phase Model of Liquid-Liquid Interactions with Interface Capturing: Application to Water Assisted Injection Molding ...... 361 L. Silva, R. Lanrivain, W. Zerguine, A. Rodriguez-Villa, and T. Coupez

Numerical Representations of Microstructures and Modeling of Their Evolutions Organized by: Roland Loge´

Full-ﬁeld Model and Experimental Validation of Subgrain Texture and Microstructure Evolution of Polycrystalline Copper ...... 369 R. A. Lebensohn, R. Brenner, and O. Castelnau Development of Numerical Tools for the Multiscale Modelling of Recrystallization in Metals, Based on a Digital Material Framework ...... 375 M. Bernacki, H. Digonnet, H. Resk, T. Coupe, and R. Loge´ Crystal-plasticity-based FE Modelling of a Dual-phase Microstructure in Which Grains Have Non-Uniform Shape and Size...... 381 M. A. Melchior, J.-F. Remacle, and L. Delannay Reducing Computational Cost and Allowing Automatic Remeshing in FEM Models of Metal Forming Coupled with Polycrystal Plasticity...... 387 R. E. Loge´,M.Be´ringhier, Y. B. Chastel, and L. Delannay Modeling of 3D Aluminum Polycrystals during Large Deformations ...... 393 A. M. Maniatty, D. J. Littlewood, J. Lu, and D. Pyle Study of Axes Rotation during Simple Shear Tests on Aluminum Sheets ...... 399 L. Ducheˆne, B. Diouf, T. Lelotte, P. Flores, S. Bouvier, and A. M. Habraken

vii Design and Optimization of Forming Processes Organized by: Subir Roy

Robust Design of Parameters Fluctuations Based on Finite Element Method and Orthogonal Array in Springback ...... 407 C. Lei, Q. Xi, and W. Junbiao 3D Simulation and Validation of Tube Piercing Process ...... 413 E. Ceretti, C. Giardini, and A. Attanasio 3D FEM Geometry and Material Flow Optimization of Porthole-die Extrusion ...... 419 E. Ceretti, L. Mazzoni, and C. Giardini Numerical Prediction of Elastic Springback in an Automotive Complex Structural Part ...... 425 L. Fratini, G. Ingarao, F. Micari, and A. Lo Franco Measuring of Geometrical Precision of Some Parts Obtained by Asymmetric Incremental Forming Process after Trimming...... 431 G. Ambrogio, L. Filice, L. Fratini, G. Ingarao, and L. Manco Numerical Design of Experiments to Analyse the Contact Conditions in Microforming ...... 437 C. Barbier, S. Thibaud, P. Picart, and J. Chambert On the Determination of the Blank Shape Contour for Thin Precision Parts Obtained by Stamping ...... 443 M. Azaouzi, A. Delame´zie`re, H. Naceur, D. Sibaud, J. L. Batoz, and S. Belouettar Topology Optimization of a Stamping Die ...... 449 A. Nilsson and F. Birath Response Surface Method for the Rapid Design of Process Parameters in Tube Hydroforming...... 455 M. S. Chebbah, H. Naceur, M. Hecini, and S. Belouettar Sensitivity Analysis and Optimization of Tube Bending Coupled with Pressure Test ...... 461 E. Beauchesne, M. Saﬁeddine, G. Marin, and E. Herbay Optimization of Forming Processes with Different Sheet Metal Alloys ...... 467 L. C. Sousa, C. F. Castro, and C. C. Anto´nio

Optimization and Robustness in Forming Organized by: A.H. van den Boogaard and Lionel Fourment

Gradient, Non-Gradient and Hybrid Algorithms for Optimizing 3D Forging Sequences with Uncertainties...... 475 L. Fourment A Study for Efﬁciently Solving Optimisation Problems with an Increasing Number of Design Variables ...... 481 S. Trichon, M. H. A. Bonte, A. H. van den Boogaard, and J.-P. Ponthot 3D Die Shape Optimization Using Direct Compensation and Surface Approximation ...... 487 B. Lu, H. Ou, and C. G. Armstrong A Robust Optimisation Strategy for Metal Forming Processes...... 493 M. H. A. Bonte, A. H. van den Boogaard, and R. van Ravenswaaij A Simpliﬁed Methodology for Estimating the Variance of Material Properties, in FE Analysis under Uncertainty of Sheet and Tube Metal Forming Processes ...... 499 M. Strano

Tools Optimisation in Forming Processes Organized by: Fabrice Schmidt and Hakim Naceur

A Fully Coupled Simulation and Optimization Scheme for the Design of 3D Powder Injection Molding Processes ...... 507 G. Ayad, J. Song, T. Barriere, B. Liu, and J. C. Gelin Implementation of the Artiﬁcial Neural Networks to Control the Springback of Metal Sheets...... 513 A. Crina

viii Simulation of the Two Stages Stretch-Blow Molding Process: Infrared Heating and Blowing Modeling ...... 519 M. Bordival, F. M. Schmidt, Y. Le Maoult, and V. Velay Cooling Channel Optimization for Injection Molding ...... 525 N. Pirc, F. Bugarin, F. M. Schmidt, and M. Mongeau Geometrical Optimization in Clinch Forming Process Using the Response Surface Method...... 531 M. Oudjenea, L. Ben-Ayed, and J.-L. Batoz Optimizations of Coat-Hanger Die, Using Constraint Optimization Algorithm and Taguchi Method...... 537 N. Lebaal, F. Schmidt, and S. Puissant

Forming Processes of Magnesium Alloys and Their Computer Simulation Organized by: Shi-Hong Zhang

Applications of Computer Simulation Methods in Plastic Forming Technologies for Magnesium Alloys ...... 545 S. H. Zhang, W. T. Zheng, Y. L. Shang, X. Wu, G. Palumbo, and L. Tricarico Finite Element Simulation of Magnesium AZ31 Alloy Sheet in Warm Hydroforming ...... 551 M. Steffensen and J. Danckert Study on Numerical Simulation and Experiment of Fabrication Magnesium Semisolid Slurry by Damper Cooling Tube Method ...... 557 S. Xie, G. Huang, X. Zhang, and H. Yang Warm Deep Drawing of Rectangular Parts of AZ31 Magnesium Alloy Sheet Adopting Variable Blank Holder Force ...... 563 Y. Peng, Q. Chang, D. Li, and X. Zeng Numerical Modeling of Magnesium Alloy Sheet Metal Forming at Elevated Temperature ...... 569 M. Lee, H. Kim, H. Kim, Y. Choi, and S. Oh Warm Deep Drawing of Rectangular Cups with Magnesium Alloy AZ31 Sheets ...... 575 L. M. Ren, G. Palumbo, S. H. Zhang, and L. Tricarico Design Optimization of Roller Straightening Process for Steel Cord Using Response Surface Methodology ...... 581 J.-S. Lee, H. Huh, J.-G. Bae, J.-W. Lee, and D.-T. Kim

Constitutive Modeling and Mechanics for Metal Forming Organized by: Rui P.R. Cardoso and Jeong-Whan Yoon

Evaluation of Flow Stresses of Tubular Materials Considering Material’s Anisotropy ...... 589 Y. Hwang and B. Chen On the Adequate Representation of Velocity Fields in a Narrow Layer Near Maximum Friction Surfaces ...... 595 Se. Alexandrov, G. Tzou, and T. Chen Study of Titanium Alloy Sheet during H-Sectioned Rolling Forming Using the Taguchi Method...... 601 D. Chen, W. Gu, and Y. Hwang On Using Homogeneous Polynomials to Design Anisotropic Yield Functions with TensionÕ Compression SymmetryÕAssymetry ...... 607 S. Soare, J. W. Yoo, and O. Cazacu Asymmetric Rolling Process Simulations by Dynamic Explicit Crystallographic Homogenized Finite Element Method ...... 613 N. Ngoc Tam, Y. Nakamura, T. Terao, H. Kuramae, E. Nakamachi, and H. Sakamoto Compressive Instability Phenomena during Springback ...... 619 J.-B. Kim, J. W. Yoon, and D. Y. Yang Comparison of Two Commercial FE-Codes for Sheet Metal Forming ...... 625 A. Revuelta, K. Kanervo, P. Myllykoski, J. Larkiola, and A. S. Korhonen A New Modelling of Blanking for Thin Sheet in Copper Alloys with Dynamic Recrystallization ...... 631 A. Touache, S. Thibaud, J. Chambert, and P. Picart

ix Flow Stress Curves Using New Volume Measurement Method for Hydraulic Bulge Test ...... 637 L. M. Smith, Y. Hadad, R. Thotakura, S. Gunala, and S. Manthipragada Finite Element Simulation of Sheet Metal Forming Using Anisotropic Strain-Rate Potentials ...... 643 M. Rabahallah, T. Balan, S. Bouvier, B. Bacroix, and C. Teodosiu Study on the Hemisphere Deep Drawing Process of Metal Sheet Based on the FEM Simulation...... 649 G. Tzou, Y. Hwang, H. Hu, W. Chien, and J. Hu Modelling the Material Behaviour of Metastable Stainless Steels ...... 655 K. Datta, H. J. M. Geijselaers, J. Post, J. Beyer and J. Hue`tink Modeling of Deformation of FCC Polycrystalline Aggregates Using a Dislocation-based Crystal Plasticity Model ...... 661 G. Abrivard, E. P. Busso, G. Cailletaud, and S. Forest Constitutive Modeling of Magnesium Alloy Sheets...... 667 M. G. Lee, K. Piao, R. H. Wagoner, J. K. Lee, K. Chung, and H. Y. Kim Convolute Cut-Edge Design for a Circular Cup Based on FEM and an Analytical Approach ...... 673 R. E. Dick, J. W. Yoon, and F. Barlat Material Models to Study the Bauschinger Effect on an Aluminum Shear Test Specimen...... 679 R. P. R. Cardoso, J.-W. Yoon, and J. J. Gra´cio Earing Prediction in Cup Drawing Based on Non-Associated Flow Rule ...... 685 J. W. Yoon, T. B. Stoughton, and R. E. Dick Kinematic Hardening: Characterization, Modeling and Impact on Springback Prediction...... 691 J. L. Alves, S. Bouvier, M. Jomaˆa, R. Billardon, M. C. Oliveira, and L. F. Menezes

Developments in Finite Element Technologies for Forming Processes Organized by: Robert A.F. Valente, Renato M.N. Jorge and Ricardo A. Sousa

Adaptive Through-thickness Integration Strategy for Shell Elements ...... 699 I. A. Burchitz, T. Meinders, and J. Hue´tink Tube Drawing Process Modelling by a Finite Element Analysis...... 705 M. Palengat, G. Chagnon, C. Millet, and D. Favier Micro Wire-Drawing: Experiments and Modelling...... 711 G. A. Berti, M. Monti, M. Bietresato, and L. D’Angelo Gurson’s Model: ALE Formulation and Strain Localization ...... 717 L. A. B. da Cunda and G. J. Creus Towards Efficient Modelling of Macro and Micro Tool Deformations in Sheet Metal Forming ...... 723 R. A. Lingbeek and T. Meinders Fluid Structure Interaction Analysis in Manufacturing MetalÕPolymer Macro-Composites...... 729 R. Baesso and G. Lucchetta Integrated Modelling of Damage and Fracture in Sheet Metal Forming ...... 735 R. H. J. Peerlings, J. Mediavilla, and M. G. D. Geers An Overview of Sheet Metal Forming Simulations with Enhanced Assumed Strain Elements ...... 741 R. A. F. Valente, R. J. A. de Sousa, R. M. N. Jorge, R. P. R. Cardoso, F. Simo˜es, J. W. Yoon, and J. Graćio Analysis of BCC Sheet Metal Forming by Polycrystalline Plasticity Method...... 747 S. Zhang, Y. Peng, D. Li, and L. Hu A New Solid-Shell Finite Element Technology Incorporating Plastic Anisotropy in Forming Simulations ...... 753 S. Reese, I. N. Vladimirov, and M. Schwarze Integration of Heat Transfer Coefficient in Glass Forming Modeling with Special Interface Element ...... 759 P. Moreau, J. Ce´sar de Sa´,S.Gre´goire, and D. Lochegnies

x PART II GENERAL TOPICS

Sheet Forming

Finite Element Simulation of Sheet Metal Forming and Springback Using a Crystal Plasticity Approach...... 769 A. Bertram, T. Bo¨hlke, A. Krawietz, and V. Schulze Residual Stress in Sheet Metal Parts Made by Incremental Forming Process ...... 775 S. Tanaka, T. Nakamura, K. Hayakawa, H. Nakamura, and K. Motomura Sensitivity Analysis of Technological and Material Parameters in Roll Forming...... 781 A. Gehring and H. Saal Crashworthiness of Aluminium Tubes; Part 1: Hydroforming at Different Corner-fill Radii and End Feeding Levels ...... 787 G. D’Amours, A. Rahem, B. Williams, M. Worswick, and R. Mayer Crashworthiness of Aluminium Tubes; Part 2: Improvement of Hydroforming Operation to Increase Absorption Energy ...... 793 G. D’Amours, A. Rahem, R. Mayer, B. Williams, and M. Worswick Numerical Prediction of Springback Shape of Severely Bent Sheet Metal ...... 799 N. Iwata, H. Tsutamori, M. Niihara, H. Ishikura, Y. Umezu, A. Murat, and Y. Yogo Springback Simulation of High Strength Steel Sheet Using Local Interpolation for Tool Surfaces ...... 805 T. Hama, C. Teodosiu, A. Makinouchi, H. Fujimoto, and H. Takuda A Study on Process Design Methods of Redrawing Square Cups...... 811 K. Isobe Research on the Effects of the Movable Die and Its Counter Force on Sheet Hydroforming ...... 817 L. X. Zhou, S. H. Zhang, and B. X. Wang Slip Line Field Applied to Deep Drawing...... 823 V. Miguel, J. Benet, J. Coello, A. Calatayud, and A. Martıńez Control of Springback in Sheet Metal U-bending through Design Experiment ...... 829 B. Chirita and G. Brabie Incremental Volumetric Remapping Method: Analysis and Error Evaluation ...... 835 A. J. Baptista, J. L. Alves, M. C. Oliveira, D. M. Rodrigues, and L. F. Menezes Influence of Drawbeads in Deep-drawing of Plane-strain Channel Sections: Experimental and FE Analysis ...... 841 M. C. Oliveira, A. J. Baptista, J. L. Alves, L. F. Menezes, D. E. Green, and A. Ghaei Study on the Influence of the Refinement of a 3-D Finite Element Mesh in Springback Evaluation of Plane-Strain Channel Sections...... 847 R. Padmanabhan, M. C. Oliveira, A. J. Baptista, J. L. Alves, and L. F. Menezes Deep Drawing Simulation of High and Ultrahigh Strength Steels under Consideration of Anisotropic Hardening ...... 853 K. Roll, A. Faust, and L. Keßler Error Analysis in Explicit Finite Element Analysis of Incremental Sheet Forming...... 859 M. Bambach and G. Hirt Process Development and Simulation for Cold Fabrication of Doubly Curved Metal Plate by Using Line Array Roll Set ...... 865 D. S. Shim, C. G. Jung, D. Y. Seong, D. Y. Yang, J. M. Han, and M. S. Han The Material Rolling Direction Influence on Springback Effect in Case of a U-shape Part Made from Tailor Welded Stripes ...... 871 A. Aurelian The Effect of Temperature Rise in a Fine Blanking Tool ...... 877 S. Kim, J. J. Kang, D. Lee, K.-Y. Lee, H.-Y. Kim, and H.-T. Kim Experimental Campaign Definition for Sheet Hydroforming through CAE Tools Usage ...... 883 A. Del Prete, A. Anglani, and G. Papadia Experimental and Numerical Investigations in Single Point Incremental Sheet Forming ...... 889 S. Dejardin, S. Thibaud, and J. C. Gelin

xi Investigation of Forming Performance of Laminated Steel Sheets Using Finite Element Analyses...... 895 W. Liu, X. Sun, R. Ruokolainen, and X. Gayden Study the Effect of Curvature on Spring Back of Double Curved Steel Sheet Using New Method...... 901 M. H. Parsa, M. Kazemi, and H. Pishbin Further Experimental Verification of a Proposed Localized Necking Criterion...... 907 Q. Situ, M. K. Jain, and M. Bruhis Some Considerations in Modeling Axisymmetric Deep Drawing and Redrawing Process and LDR Prediction ...... 913 S. Han, M. Bruhis, and M. K. Jain FETI-INDEED: New Perspectives in Metal Forming Simulation...... 919 K. Kassem-Manthey, M. Grauer, R. Lenz, and R. Menzel Impact of Elastic Modulus Degradation on Springback in Sheet Metal Forming ...... 925 M. Halilovicˇ, M. Vrh, and B. Sˇtok A Study on Segmented Multiple-step Forming of Doubly Curved Thick Plate by Reconfigurable Multi-Punch Dies ...... 931 Y. H. Ko, M. S. Han, and J. M. Han Adaptive Refinement Procedure for Sheet Metal Forming ...... 937 A. Cherouat, L. Giraud-Moreau, and H. Borouchaki Correlation of FEA Prediction and Experiments on Dual-phase Steel Automotive Rails ...... 943 C. Du, X. M. Chen, T. Lim, T. Chang, P. Xiao, and S.-D. Liu Computationally Efficient Finite Element Analysis Method Incorporating Virtual Equivalent Projected Model for Metallic Sandwich Panels with Pyramidal Truss Cores...... 949 D. Seong, C. Jung, and D. Yang Sectional Finite Element Analysis on Viscous Pressure Forming of Sheet Metal ...... 955 J. Liu, Z. Wang, and Y. Liu

Bulk Forming

A Comparison between the Properties of Solid Cylinders and Tube Products in Multi-pass Hot Radial Forging Using Finite Element Method...... 963 A. Abedian, M. Poursina, and H. Golestanian Practice of Process Modeling of Metal Forming in Manufacturing Environment ...... 969 M. He A New Method for Reducing Dimensional Variability of Extruded Hollow Sections ...... 975 T. Welo, H. A. Baringbing, and O. P. Søvik Analytic Model for Estimation of Cold Bulk Metal Forming Simulations ...... 981 M. Skunca, Z. Keran, and M. Math Process Modelling of IN718 for Free Forging ...... 987 H. Yoshida, T. Hatta, T. Hironaka, and S. Isogawa, and H. Sekiguchi Effect of Flaw Removal on Billets in Rolling...... 993 K. Yoshida and T. Shinohara Investigations on Forging Dies with Ceramic Inserts by Means of Finite-element Analysis...... 999 B.-A. Behrens, F. Scha¨fer, and M. Bistron The Relevance of the Preform Design in Coining Processes of Cupronickel Alloy ...... 1005 G. Buffa, L. Fratini, and F. Micari Analysis of Axisymmetrical Compression Processes by the Finite Element Method ...... 1011 A. M. Camacho, M. Marin, L. Sevilla, and M. A. Sebastian Elasto-plastic Simulation Concepts for Proﬁle Transfer and Flatness Prediction in Flat Hot Rolling ...... 1017 A. Kainz, E. Parteder, M. Widder, and K. Zeman Numerical Simulation of Damage during Forging with Superimposed Hydrostatic Pressure by Active Media...... 1023 B.-A. Behrens, T. Hagen, S. Ro¨hr, and K. B. Sidhu Computer Simulation of Material Flow in Warm-forming Bimetallic Components ...... 1029 T. F. Kong, L. C. Chan, and T. C. Lee

xii Flash Design Optimization in Blade Forging Using FEM Method...... 1035 D. Shahriari, M. H. Sadeghi, M. Cheraghzadeh, and M. Taghipour Optimal Cluster Mill Pass Scheduling with an Accurate and Rapid New Strip Crown Model ...... 1041 A. S. Malik, R. V. Grandhi, and M. E. Zipf Use of a TiBN Multilayer Coating for Wear Reduction...... 1047 B. Behrens, F. Bach, K. Moehwald, T. A. Deißer, and M. Bistron

Casting, Molding, Quenching

Simulation of an Aspheric Glass Lens Forming Behavior in Progressive GMP Process ...... 1055 S. H. Chang, Y. M. Lee, T. S. Jung, J. J. Kang, S. K. Hong, G. H. Shin, and Y. M. Heo A Model for Prediction of Shrinkage Defects in Long and Short Freezing Range Materials...... 1061 A. Reis, Z. Xu, A. D. Santos, J. F. Duarte, and A. B. Magalha˜es Application of Moldex3D for Thin-wall Injection Moulding Simulation ...... 1067 M. Sˇercer, D. Godec, and B. Bujanic´ Numerical Simulation of Horizontal Continuous Casting Process of C194 Copper Alloy...... 1073 G. Huang, S. Xie, L. Cheng, and Z. Cheng Modeling and Simulation of the Flow of a Thermoplastic Polymer during Filling of a Cylindrical Micro-Cavity ...... 1079 M. Sahli, J. C. Gelin, C. K. Malek, and C. Roques-Carmes

Materials, Joining, and Powder Forming

Development of the Fast FE Method for Welding Deformation ...... 1087 Y. Yogo, N. Goto, N. Iwata, K. Nakanishi, and S. Yagishita Stress-strain Analysis of Single-lap Tensile Loaded Adhesive Joints ...... 1093 P. Raos, D. Kozak, and M. Lucic´ Development of MetalÕPolymer Mixtures Dedicated to Macro and Micro-powder Injection Moulding: Experiments and Simulations ...... 1099 C. Quinard, T. Barrie`re, J. C. Gelin, J. P. Song, Z. Q. Cheng, and B. S. Liu Thermo-mechanical Calculations of Hybrid Rotary Friction Welding at Equal Diameter Copper Bars and Effects of Essential Parameters on Dependent Special Variables ...... 1105 M. H. Parsa, H. Davari, A. M. Hadian, and M. N. Ahmadabadi Numerical Simulation of Sintering Process in Ceramic Powder Injection Moulded Components ...... 1111 J. Song, T. Barriere, B. Liu, J. C. Gelin Modelling and Simulation of Tensile Fracture in High Velocity Compacted Metal Powder ...... 1117 P. Jonse´n and H-Å Ha¨ggblad Numerical Analysis of the Resistance to Shear Test of Clinched Assemblies of Thin Metal Sheets ...... 1123 M. Jomaˆa and R. Billardon

Machining

New Modelling Strategies for Metal Cutting ...... 1131 P. A. R. Rosa, P. A. F. Martins, and A. G. Atkins 3D Simulation of Adiabatic Shear Bands in High Speed Machining ...... 1137 F. Delalondre, S. Guerdoux, and L. Fourment Some Considerations on the FE Simulation of Orthogonal Cutting Using Different Classes of Numerical Codes ...... 1143 S. Rizzuti, L. Filice, and D. Umbrello FE Thermal Modelling of Machining with Ball End Milling ...... 1149 A. Nasri, L. Sayari, M. Ben Said, W. Bouzid, and O. Tsoumarev Modelling of Tool Wear and Residual Stress during Machining of AISI H13 Tool Steel ...... 1155 J. C. Outeiro, D. Umbrello, J. C. Pina, and S. Rizzuti Analytical Modelling of Milling for Tool Design and Selection ...... 1161 M. Fontaine, A. Devillez, and D. Dudzinski

xiii A Numerical Study of the Mechanical Behavior of Silicon Carbide due to Pressure-induced Phase Transformations during Nanoindentation ...... 1167 R. Mariayyah, K. Bose, and H. Cherukuri

Thermal Mechanical Processing

Warm Hydroforming of Lightweight Metal Sheets...... 1175 A. Aginagalde, A. Orus, J. A. Esnaola, I. Torca, L. Galdos, and C. Garcı´a Simulation and Evaluation of Phase Transformations and Mechanical Response in the Hot Stamping Process ...... 1181 M. Oldenburg, P. Åkerstro¨m, G. Bergman, and P. Salomonsson Mesh Re-zoning in Multi-stand Rolling ...... 1187 K. Subramanian, R. S. Minisandram, and H. P. Cherukuri Analysis of Molding Process for Epoxy Resin Used for Electrical Insulator...... 1193 Y. Kushizaki and T. Yamada Simulation and Experimental Results of the Hot Metal Gas Forming Technology for High Strength Steel and Stainless Steel Tubes Forming...... 1199 L. Vadillo, M. T. Santos, M. A. Gutierrez, I. Pe´rez, B. Gonza´lez, and V. Uthaisangsuk Analysis of Deformation Behavior of Plastic during Lining on Steel Pipe with an FEM ...... 1205 T. Yamada, T. Maikawa, and Y. Kushizaki

Methods for Material and Process Design

Impact of the Material Variability on the Stamping Process: Numerical and Analytical Analysis ...... 1213 Y. Ledoux, A. Sergent, and R. Arrieux Optimisation of Shape Parameters and Process Manufacturing for an Automotive Safety Part...... 1219 E. Gildemyn, P. Dal Santo, A. Potiron, and D. Saı¨dane Experimental and Numerical Investigation of Forging Process to Reproduce a 3D Aluminium Foam Complex Shape ...... 1225 L. Filice, F. Gagliardi, R. Shivpuri, and D. Umbrello Determination of Slitting Criterion Parameter during the Multi Slit Rolling Process ...... 1231 A. Stefanik, S. Mro´z, P. Szota, and H. Dyja Application of Numerical Modelling to Ribbed Wire Rod Dimensions Precision Increase...... 1237 P. Szota, S. Mro´z, and A. Stefanik Modelling of Rolling and Cooling Processes of the Bulb Bars HP220 ...... 1243 S. Mro´z, P. Szota, and B. Koczurkiewicz Statistical Tools and Artiﬁcial Intelligence Approaches to Predict Fracture in Bulk Forming Processes ...... 1249 R. Di Lorenzo, G. Ingarao, and V. Fonti Fatigue Life Prediction in Rapid Die Casting—Preliminary Work in View of Current Research...... 1255 C. H. Ng, K.-H. Grote, and R. Ba¨hr

Material Characterization

Forming Limit Prediction of Metastable Materials with Temperature and Strain Induced Martensite Transformation...... 1263 J. Krauer, P. Hora, L. Tong, and B. Berisha Plastic Deformation Characteristics of AZ31 Magnesium Alloy Sheets at Elevated Temperature ...... 1269 J. Park, J. Lee, B. You, S. Choi, and Y. Kim Experimental and Numerical Study of the Thermomechanical Behavior of a Stamping Operation ...... 1275 L. Yann, L. Herve´, V. Pierre, and A. Robert Tube Bulge Process: Theoretical Analysis and Finite Element Simulations ...... 1281 R. Velasco and N. Boudeau

xiv Estimation of Rheological Law by Inverse Method from Flow and Temperature Measurements with an Extrusion Die ...... 1287 C. Pujos, N. Regnier, P. Mousseau, G. Defaye, and Y. Jarny

Inelastic Material Models

Elastic-plastic Constitutive Equation of WC-Co Cemented Carbides with Anisotropic Damage...... 1295 K. Hayakawa, T. Nakamura, and S. Tanaka Finite Stain Viscoelastic-plastic Deformation of Polymers Using Finite Element Simulation ...... 1301 K. Hasanpour and S. Ziaei-Rad A Coupled Model of Flow Stress and Microstructure Evolution ...... 1307 D. S. Svyetlichnyy On the Modeling of Plastic Deformation of Magnesium Alloys ...... 1313 S. Ertu¨rk, D. Steglich, J. Bohlen, D. Letzig, and W. Brocks A Flow Stress Formulation of Magnesium Alloy at Elevated Temperature...... 1319 J. Liu, Z. Cui, and L. Ruan Finite Element Analysis of Polycrystalline Deformation with the Rate-dependent Crystal Plasticity ...... 1325 J. H. Yoon, H. Huh, and Y. S. Lee Accurate Hardening Modeling as Basis for the Realistic Simulation of Sheet Forming Processes with Complex Strain-path Changes ...... 1331 V. Levkovitch and B. Svendsen A Mathematical Model for Plasticity and Cosmology ...... 1337 J. D. Mun˜oz-Andrade

Multi-Scale Modelling

A Multiscale Model Based on Intragranular Microstructure: Inﬂuence of Grain-scale Substructure on Macroscopic Behaviour of an IF-Steel during Complex Load Paths ...... 1345 G. Franz, F. Abed-Meraim, T. B. Zineb, X. Lemoine, and M. Berveiller Forming Simulations of MMC Components by a Micromechanics Based Hierarchical FEM Approach...... 1351 C. O. Huber, M. H. Luxner, S. Kremmer, S. Nogales, H. J. Bo¨hm, and H. E. Pettermann Three-dimensional Cellular Automata for Simulation of Microstructure Evolution during Recrystallization...... 1357 D. S. Svyetlichnyy and J. L. Matachowski 3D Modeling of Sintering—Case of Two Grains ...... 1363 M. Ajdour, J. Le´chelle, F. Valdivieso, and P. Goeuriot Two-phase Multiscale FEM Modelling of Macrosegregation Formation in Steel Slabs...... 1369 M. Bellet The FEM Simulation of Cementite Lamellas Deformation in Pearlitic Colony during Drawing of High Carbon Steel...... 1375 A. Milenin and Z. Muskalski Multiscale Simulations of the Elastic Properties of Polycrystalline Silicon ...... 1381 H. Kim, W. Windl, J. Choi, J. K. Lee, and N. K. Lee

Damage Evolution and Failure

Damage Evolution on Mechanical Parts Under Cyclic Loading ...... 1389 P. Lestriez, F. Bogard, J. L. Shan, and Y. Q. Guo Numerical Simulation of Burst Defects in Cold Extrusion Process ...... 1395 C. Laberge`re, P. Lestriez, and K. Saanouni Stress Limit Model with Deformation Dependent Damage for Failure Prediction in Bulk Forming Processes ...... 1401 P. Hora, L. Tong, and B. Berisha

xv Prediction of the Fracture due to Mannesmann Effect in Tube Piercing ...... 1407 S. Fanini, A. Ghiotti, and S. Bruschi Evaluation of Fracture in a Three Stage Forging Process Using Continuum Damage Mechanics ...... 1413 M. Mashayekhi, S. Ziaei-Rad, J. Parvizian, and H. Hadavinia A Finite Element Approach to Mechanical Degradation and Failure of Ductile Materials ...... 1419 M. Vaz, Jr., N. de Santi, Jr., and E. A. de Souza Neto Aging Damage Effects on Composite Structures...... 1425 B. Freitas de Oliveira and G. J. Creus

Formability and Fracture

Evaluation of Forming Limit by the 3 Dimensional Local Bifurcation Theory ...... 1433 R. Nishimura, K. Ito, Y. Nakazawa, G. Uemura, and N. Mori Formability Analysis of Magnesium Alloy Sheet Bulging Using FE Simulation...... 1439 B. J. Mac Donald, D. Hunt, S. Yoshihara, and K. Manabe Failure Analysis With a New Tool Geometry, X-Die, in Areas with High TensionÕCompression Strains ...... 1445 A. Andersson and P. Thilderkvist Numerical and Experimental Studies on Strain Distribution and Weld Line Movement in Stretch Forming of Tailor Welded Blanks ...... 1451 S. K. Panda and D. R. Kumar Finite Element Modeling of Transition Zone in Friction Stir Welded Tailor-made Blanks ...... 1457 A. A. Zadpoor, J. Sinke, and R. Benedictus Numerical and Experimental Investigations into Tailored Welded Blanks Formability ...... 1463 S. Gaied, F. Pinard, F. Schmidt, and J.-M. Roelandt

Numerical Methods and Applications

Development and Applications of Simulation System JSTAMPÕNV for Tube Hydro-Forming ...... 1471 N. Ma, Y. Umezu, and Y. Watanabe New Method to Evaluate and Compensate 3D-Springback ...... 1477 K. Ito, T. Kondou, G. Uemura, and N. Mori Smoothed Particle Hydrodynamic Simulation of Iron Ore Pellets Flow ...... 1483 G. Gustafsson, H.-Å. Ha¨ggblad, and M. Oldenburg Modeling the Interaction Effects between Tools and the Work Piece for Metal Forming Processes ...... 1489 M. Franzke, S. Puchhala, and H. Dackweiler An eXtended Arbitrary Lagrangian-Eulerian Finite Element Model „X-ALE-FEM… in Large Plasticity Deformations ...... 1495 A. R. Khoei, M. Anahid, and K. Shahim Decoupled Simulation Method for Incremental Sheet Metal Forming...... 1501 G. Sebastiani, A. Brosius, A. E. Tekkaya, W. Homberg, and M. Kleiner Coupling Finite Element and Meshless Methods to Deal with Contact and Friction in Forging Processes ...... 1507 C. F. Guedes and J. M. A. Ce´sar de Sa´ Finite Element Technology in Forming Simulations—Theoretical Aspects and Practical Applications of a New Solid-shell Element...... 1513 M. Schwarze and S. Reese Integration of the Security Sub-modules Elements in the Automotive Industry ...... 1519 C. Gallego, M. Ferna´ndez, A. S. Caires, and E. Can˜ibano Numerical Simulations of Moving Interfaces by Level Set Method in the Partition of Unity Concept ...... 1525 M. Istrate and G. Winkelmuller Predicting Distributive and Dispersive Mixing in Polymer Extrusion ...... 1531 N. Domingues, A. Gaspar-Cunha, and J. A. Covas

xvi The Use of DEM to Capture the Dynamics of the Flow of Solid Pellets in a Single Screw Extruder ...... 1537 H. Hong, J. A. Covas, and A. Gaspar-Cunha Level-Set Method Used to Track the Glass-air Interface in the Blow Step of Glass Containers ...... 1543 C. G. Giannopapa and J. A. W. M. Groot

Macroscopic Electromechanical Behavior of Polycrystalline Piezoelectric Materials BaTiO3 and PbTiO3; a 3D Analysis...... 1549 K. P. Jayachandran, J. M. Guedes, and H. C. Rodrigues Numerical Computation of the Heat Transfer Coefficient in the 2-D Inverse Design Stefan Problem ...... 1555 D. Słota Adaptive Anisotropic Mesh Technique for Coupled Problems: Application to Welding Simulation ...... 1561 M. Hamide and M. Bellet Identification of Constitutive Parameters Using Inverse Strategy Coupled to an ANN Model ...... 1567 H. Aguir, A. Chamekh, H. BelHadjSalah, and R. Hambli Implementation of the eXtended Finite Element Method „X-FEM… in Frictional Contact Problems ...... 1573 A. R. Khoei, M. Anahid, I. Yadegaran, and M. Nikbakht Parallel 3D Mesh Generation Using Geometry Decomposition...... 1579 T. Jurczyk, B. Głut, and P. Breitkopf On Scalability of Distributed Simulation and Optimization of Forming Processes ...... 1585 F. Thilo, M. Grauer, R. Menzel, and C. Mu¨ller Integrated Forming Simulation Using State-of-the-Art Methodologies ...... 1591 D. Ling, J.-L. Babeau, M. Skrikerud, Y. Dammak, and F. El Khaldi Thermal Conductivity of SWCNT Nanocomposites Determined Using Finite Element Method ...... 1597 H. Golastanian and M. Poursina FE Simulation of Dieless Drawing Process for Small-size Non-circular Tubes ...... 1603 T. Furushima and K.-I. Manabe A Nonconforming Multidomain Method for Contact Problems ...... 1609 J. A. Rodrigues Problems of Numerical Modelling of Processes Determined by Shear Fracture ...... 1615 E. S. Dzidowski and S. Lawrusewicz Warm Forming Simulation of Titanium Tailor-welded Blanks with Experimental Verification ...... 1621 C. P. Lai, L. C. Chan, and C. L. Chow

Author Index ...... A1

xvii