FAST SIMULATION SYSTEM FOR AXISYMMETRICAL STAMPED-PARTS DEFORMATION

Taking into account, as soon as possible in the product design process , specific manufacturing constraints is a major stake in the current e conomic context. In the specific field of forging part design, i.e. th e modification of the initial shape of the tooled part into a forgeabl e shape, our recent developments show the necessity of knowing the way the material flows during the process. To this end, we are developing a fast-simulation deformation tool (two dimensional, isothermal) base d on the extension of Chamouard's model. This tool allows us to simula te the evolution of the forging force, as well as to visualise the int ermediate shapes during the operation in order to identify the critica l zones in terms of filling. In this paper, we present our latest deve lopments about this subject. First of all, we deal with the problem of the upsetting of a billet, recalling the model used and in particular our original approach to the evolution of the tool/part contact diame ter. Then we present the extension to the flashless forging of a bille t and we compare our results to experimental ones from the literature. This comparison relies on the correlation between the forging force a nd the unfilled volume, i.e. a measurement of the corresponding corner radius. The integration of the flash calculation is the third main po int of this paper. After a detailed presentation of the model, we show its sensitivity to the flash position on the part. Then we also compa re the obtained results with those in the literature. We end with the presentation of an example showing the current abilities of the progra m in terms of algorithms' performance, interface facilities and result handling.