Modeling Dynamic Blanking / Stamping of Slot Bridges in Sheet Metal for Residual Stress and Springback Analysis
Fabian Duckhorn
Dear LS-DYNA users,
I am looking for examples and/or advice on how to model a dynamic blanking / stamping process of slot bridges in sheet metal (see image) in order to evaluate the resulting stresses and strains. The goal is to use these results for subsequent processes or for the characterization of homogenized material properties.
Therefore, the cut edge quality itself is not of primary interest.
The process includes shear cutting and forming of the sheet metal.
From my understanding, the current state of the art for metal cutting simulations is the Element-Free Galerkin (EFG)method. However, EFG does not seem to be well suited for springback analysis.
At the moment, I see two possible solution strategies, with the second one being my preferred option:
1. Hybrid EFG / Shell approach
Use EFG locally in the cutting regions (sides of the slot bridge)
Model the bridge itself using shell elements for bending
Perform an explicit–implicit switch for springback analysis
Expected drawbacks:
Difficult model setup for representing a whole plate while only one bridge is evaluated
High computational cost
2. Lagrangian approach with cohesive elements (preferred)
Use Lagrangian solid/shell elements
Introduce cohesive elements in the cutting region
Use shell elements for the remaining sheet
Apply an explicit–implicit switch for springback analysis
Expected advantages:
Suitable for crack propagation analysis in further characterization of the slotted plate
Accurate springback prediction
Computationally more efficient than EFG-based approaches
If anyone has suggestions, best practices, or example models for similar blanking or stamping processes (especially with a focus on residual stresses rather than cut surface quality), I would greatly appreciate your input.
Thank you in advance.