Numerical Algorithm and Software Development for Metal Forming

To develop a customized computer-aided engineering (CAE) software with specialized features for metal forming, based on the self-developed OmtDesk platform, a numerical algorithm for mental forming calculation is proposed. On the basis of the bipotential theory, the Uzawa algorithm was applied to addressing the frictional contact. The return-mapping algorithm was then applied in the framework of the updated Lagrangian to analyze the non-linearity of metal materials. Furthermore, two numerical tests in terms of compression springback and extrusion forming were conducted for verifying the accuracy and feasibility of the developed CAE software with the aid of FEM and Form simulation software. The results are compared with those by ANSYS. In the case of the compression springback test, the penetration value calculated by ANSYS software has a magnitude of 10^–3 mm, whereas those by FEM and Form software show a penetration magnitude of 10^–7 mm. This demonstrates that the proposed bipotential contact module can effectively control the penetration value in the simulation of metal forming, thereby improving the precision of the metal forming process.