Quasi-symmetrical contact algorithm and recurrent boundary conditions: application to 3d metal forging simulations

Abstract : In industry, the numerical simulation of material forming processes is a powerful method of cutting development costs. The finite element analysis software FORGE3® was created to solve large deformations thermo mechanical problems with non-linear material behavior and several deformable bodies. The first part of this thesis presents the application of the repetitive symmetries necessary to reduce the CPU time for the helical gear forging simulation. This type of boundary condition is handled as a special bilateral sticking contact condition between the two symmetry surfaces of the same body, using a master-slave algorithm. Then a similar method is used to apply the contact conditions between the workpiece and the deformable tools, also running the simulation on a reduced domain. A first test series proves the reliability of this method. The second part deals with the improvement of the deformable bodies contact condition with non-coincident meshes. A nodal penalized quasi-symmetric formulation is used to apply the contact equation. This approach allows applying proper boundary conditions on all the nodes of the two surfaces in contact without providing an over constraint problem. A second test series, both academic and industrial shows on one hand the improved accuracy and convergence rate of the new metho
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Sorin Popa. Quasi-symmetrical contact algorithm and recurrent boundary conditions: application to 3d metal forging simulations. Engineering Sciences [physics]. École Nationale Supérieure des Mines de Paris, 2005. English. ⟨NNT : 2005ENMP1422⟩. ⟨pastel-00002047⟩

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