Application of the incremental volumetric remapping method in the simulation of multi-step deep drawing processes

Abstract

Since sheet metal forming has a high percentage contribution in the overall design costs of a new car, this engineering area assisted in the last decades to considerable development efforts. The present challenge is to simulate all the production stages, from the initial blank sheet to the final part ready to assembly. On this particular issue of multi-step deep-drawing simulation, this work presents a new remapping method called Incremental Volumetric Remapping (IVR) developed to minimize the error that occurs, when performing the variable transfer operation between two different meshes. The IVR method is based in a volumetric approach where the calculus of the remapped state variables is obtained by means of a weighted average of the intersection volume between the meshes. The method performance is tested and compared with a standard extrapolation-interpolation, by applying a numerical example of the Numisheet'005 Conference, "The Channel Draw/Cylindrical Cup Benchmark".