Use of Numerical Simulations to Model Non-Conventional Metal Forming

This presentation was made at the 2019 NAFEMS World Congress in Quebec Canada

Resource Abstract

Four real-world applications from national laboratories and manufacturing companies are selected as the examples to demonstrate the use of ANSYS Multiphysics solution in the simulations of non-conventional metal forming: electromagnetic forming, hydrodynamic forming, and explosive forming. Numerical considerations on how to approach and effectively simulate these forming processes are discussed. In the examples of electromagnetic forming, ANSYS Maxwell and ANSYS Autodyn are coupled together to simulate the forming process of electromagnetic hammer and electromagnetic joint on a hollow copper cylinder. In the examples of hydrodynamic forming and explosive forming, Autodyn multi-material Euler solver and its unique coupled multi-solver approach are employed to simulate the process of transforming a circular steel tube into a rectangular tube through pressurized water as well as manufacturing a container from a pre-formed thin steel sheet by explosive force. These examples successfully demonstrate the numerical approach of simulating non-conventional metal forming. ANSYS Multiphysics solution is proved to be the effective numerical tool for design engineers who are working on metal forming and manufacturing.