Nonlinear finite element analysis of machining and sheet metal forming

Simulations are presented of machining and multistage sheet metal forming t hat improve on the accuracy of existing approaches by incorporating accurat e representations of additional physical phenomena. In the finite element s imulation of machining, chip formation is simulated without using a separat ion criterion. This capability has been successfully used to investigate fu ndamental aspects of machining such as the shape of the primary and seconda ry shear zones, chip curl, the size effect, and the uniqueness of machining . The analysis of multistage forming incorporates the effects of material p roperty changes due to heat treatments between forming stages. Results of s imulated forming operations are employed to evaluate the effectiveness of i ntermediate die shapes and heat treatments in improving the sheet metal for mability. It is found that intermediate heat treatments enhance the ability of intermediate die shapes to promote uniform deformation of the sheet.