Numerical Simulation of Manufacturing Processes

Recommended Prerequisites

Computer Programming, Technical Drawing, Linear Algebra, Numerical and computational methods, Elasticity and Plasticity, Thermodynamics, Solid Mechanics, Manufacturing processes, Heat Transfer, Fluid Mechanics.

Teaching Methods

Lectures of the content defined in the program and practical classes with the use of the numerical tools available, including finite element codes. Autonomous problem solving, using these numerical tools, which stimulate the integration of knowledge. Performing a project that involves the development of a numerical simulation model of a forming process and its subsequent use in the selection of process parameters.

Learning Outcomes

This course focuses on the numerical simulation of manufacturing processes, characterized as nonlinear problems. At the end of the course, the student should be able to identify: (1) the types of nonlinearities; (2) the types of kinematic formulations and time integration methods; (3) the constitutive models for describing the mechanical behaviour of deformable materials; (4) the types of spatial discretization (deformable and rigid bodies); that can be used for different technological processes. The student should also be able to develop a numerical simulation model of a forming process.

The aim is also to contribute to the development of the following generic skills in students: practical application of theoretical knowledge; oral and written communication; computer skills; critical thinking and independent learning; adaptability to new situations; and self-criticism.

Work Placement(s)

No

Syllabus

1. Introduction to nonlinear problems. Definition of nonlinearities related with geometry, material and boundary conditions.

2. Continuum mechanics in large deformation. Kinematics of large deformations. Static and dynamic formulations. Implicit and explicit time integration.

3. Mechanical and thermomechanical behaviour of materials. Anisotropic yield criteria and hardening laws. Strategies for the identification of the constitutive parameters.

4. Treatment of evolving boundary conditions. Modelling and numerical treatment of contact with friction problems. Friction models.

5. Spatial discretization of deformable and rigid bodies. Types of finite elements and spatial integration.

6. Importance of experimental validation.

Head Lecturer(s)

Marta Cristina Cardoso de Oliveira

Assessment Methods

Assessment
Project: 50.0%
Resolution Problems: 50.0%

Bibliography

 

- M. Schäfer, Computational Engineering – Introduction to Numerical Methods, Springer-Verlag Berlin Heidelberg, 2006.

- O.C. Zienkiewicz, R.L. Taylor, D.D. Fox, The finite element method: for solid & structural mechanics (Seventh Edition), Butterworth-Heinemann, 2014.

- H. Tschaetsch, Metal Forming Practise: Processes – Machines – Tools, Springer-Verlag Berlin Heidelberg, 2006.

- Taylan Altan (Eds.), Metal Forming Handbook /Schuler, Springer-Verlag Berlin Heidelberg, 1998.

- G. Chryssolouris, Manufacturing Systems: Theory and Practice, Springer Science-i-Business Media, Inc., 2006.

- P. Wriggers, Computational Contact Mechanics, Springer Berlin Heidelberg New York, 2001.

- L.E. Malvern, Introduction to the Mechanics of a Continuous Medium, PrenticeHall, 1971

- D. Banabic, Formability of metallic materials: plastic anisotropy, formability testing, forming limits, Springer, Berlin, 2000.