Manufacturing Process Simulation using Explicit Dynamics

A​bstract

In this presentation, Trevor Dutton will review the role of explicit FEA solvers in the analysis of metal forming processes. After a review of development since the 1980s, noting the key challenges which have driven innovation, Trevor will discuss the main features of explicit solvers that make it suitable for analysis of such processes, with a particular focus on sheet metal forming for the automotive and aerospace sectors. He will describe some of the important innovations required within the solvers, including new material models and, contact methods – along with some of the post-processing techniques including the all-important Forming Limit Diagram. Practical aspects of the simulation including run time optimisation – such as mesh adaptivity and mass scaling – and model validation will be noted. Finally, the presentation will mention the role of other solvers (implicit, inverse) in conjunction with explicit before concluding with key things to consider for a successful forming simulation.

About the presenter

Trevor graduated from Durham University in 1986 with a 1st Class Honours degree in Engineering Science. He has worked in the field of non-linear finite element analysis since graduating, and from the early 90’s developed considerable experience in the simulation of sheet metal forming processes.

Trevor founded Dutton Simulation Ltd In 2003, providing solutions to the manufacturing industry in the form of software, consultancy support and research & development. He is the author of the NAFEMS publication “Why Do Manufacturing Simulation” (2017), along with a number of papers and articles for the NAFEMS community. Trevor is also the Chair of the MANWG Metals Focus Group.