Méthode itérative de recherche de l'état stationnaire des procédés de mise en forme : application au laminage

Abstract : The aim of this study is to reduce the computational time for the simulation of continuous material forming processes with Forge3® software. These processes, like rolling and wire drawing, are characterized by an important length of the pieces in comparison to their sectional's dimensions and to the local contact area. A general and incremental approach requires important computational times ranging from a few hours to several days. By focusing on the quasi permanent regime of these processes, a stationary approach is developed to speed up their simulation. The computational domain consists of an initial guess of the steady flow near the tools. A domain correction stage is added after the computation of the steady flow. As boundary conditions are changed, these two stages are repeated until the convergence is reached.Most of the works is concentrated on the domain correction which is a free surface problem solved by the finite elements method. As it is a case of a pure convection problem where the treatment of contact is necessary, weak formulations have to show up an upwind shift (SUPG). Two new formulations based on the least squares method have been successfully developed (MC_supg, MC_lc). To take into account complex geometries, severals new methods have been developed by adding a second degree of freedom for surface nodes. The most efficient method (CSL_dif) uses this second degree of freedom for free surface computation only for nodes belonging to geometric edges, whereas the other nodes have a mesh regularization in tangent direction of the surface. Excellent results are obtained for many analytical test cases. A penalization method is used to apply contact equations on nodes. In order to enforce the coupling between this stage and the one for the computation of the flow, a bilateral sliding contact is assigned to the nodes in compression, whereas for the others a unilateral contact is used. A specific algorithm has been developed to efficiently compute the contact area.This iterative formulation for the search of the steady state is successfully used on a large number of material forming test cases. Important accelerations are gained compared to Forge3®, ranging from 10 to 60.
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Ugo Ripert. Méthode itérative de recherche de l'état stationnaire des procédés de mise en forme : application au laminage. Mécanique des matériaux [physics.class-ph]. Ecole Nationale Supérieure des Mines de Paris, 2014. Français. ⟨NNT : 2014ENMP0006⟩. ⟨pastel-01018391⟩

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