Sectional finite element analysis on viscous pressure forming of sheet metal

Viscous pressure forming (VPF) is a recently developed sheet flexible-die forming process, which uses a kind of semi-solid, flowable and viscous material as pressure-carrying medium that typically applied on one side of the sheet metal or on both sides of sheet metal. Different from traditional sheet metal forming processes in which sheet metal is the unique deformation-body, VPF is a coupling process of visco-elastoplastic bulk deformation of viscous medium and elasto-plastic deformation of sheet metal. A sectional finite element model for the coupled deformation between visco-elastoplastic body and elasto-plastic sheet metal was proposed to analyze VPF. The resolution of the Updated Lagrangian formulation is based on a static approach. By using static-explicit time integration strategy, the deformation of elasto-plastic sheet metal and visco-elastoplastic body can keep stable. The frictional contact between sheet metal and visco-elastoplastic body is treated by penalty function method. Using the proposed algorithm, sheet metal viscous pressure bulging (VPB) process is analyzed and compared with experiments. A good agreement between numerical simulation results and experimental ones proved the efficiency and stability of this algorithm.