Static‐explicit elastic plastic finite element simulation and virtual manufacturing of sheet metal forming

Describes the development of a static‐explicit type finite‐element formulation based on non‐linear elastic plastic shells, non‐linear contact friction and Barlat anisotropic plasticity with modified corner theory. Newly introduces the spin of the anisotropic axes as a means of deriving the objective stress rate. Demonstrates that a C⁰ continuous shell is an efficient finite element for large‐scale computation. Uses membrane shell theory to derive a kinematic description of the external contact force. Offers an explanation of the ways in which the material, press load and lubrication affect the deformation and strain localization in the automotive sheet metal forming process. Demonstrates a trial of virtual manufacturing incorporating finite‐element simulation, a visualized inspection system and a heuristic process optimization scheme.