Multi-objective finite element simulations of a sheet metal forming process via a knowledge based cloud simulation platform

Abstract

Multi-objective finite element simulation of hot stamping of aluminium alloys was developed through an enabling simulation technique known as ‘Knowledge Based Cloud – Finite Element (KBC-FE)’ simulation. KBC-FE is the enabling simulation technique that operates on a dedicated cloud based simulation platform. While the core FE simulation is conducted using a commercial FE code, e.g. PAM-STAMP, advanced predictive models were implemented through the KBC-FE technique, offering alternative to sub-routines and broaden the advanced models applications to achieve multi-objective simulations. Multi-objective simulations comprise of individual advanced functional modules, each with its own speciality in the field of hot stamping. Advanced functional modules are research oriented, modules were constructed and collaborated, such that the post-form characteristics of a hot stamped component can be assessed from multiple aspects based on a conventional finite element simulation. The capability of advanced functional modules is demonstrated through the case studies of several hot formed AA6082 components, including monolithic blanks and tailor welded blanks of different thicknesses. A hot formed component undergoes non-isothermal and non-linear loading conditions during forming, resulting in complicated thermo-mechanical deformation history. The formability and post-form strength of the hot stamped components were predicted using specialised functional modules through the KBC-FE simulation technique. For each functional module, the module was constructed using relevant advanced phenomenological based predictive models, and were experimentally verified where good agreements were obtained. Multi-objective simulations were achieved base on validated modules, demonstrated by a U-shaped components that was successfully predicted and formed. The KBC-FE simulation technique allows multi-objective FE simulations to be conducted on a cloud-computing environment, which effectively reduces computation resources and expands the capability of FE simulation software. The KBC-FE simulation technique allows frontier research to be digitalised and its benefits are maximised through knowledge sharing and cross disciplinary knowledge integration.