Explicit dynamic analysis of sheet metal forming processes using linear prismatic and hexahedral solid-shell elements

Abstract

Purpose The purpose of this paper is to propose two linear solid-shell finite elements, a six-node prismatic element denoted SHB6-EXP and an eight-node hexahedral element denoted SHB8PS-EXP, for the three-dimensional modeling of thin structures in the context of explicit dynamic analysis. Design/methodology/approach These two linear solid-shell elements are formulated based on a purely three-dimensional (3D) approach, with displacements as the only degrees of freedom. To prevent various locking phenomena, a reduced-integration scheme is used along with the assumed-strain method. The resulting formulations are computationally efficient, as only a single layer of elements with an arbitrary number of through-thickness integration points is required to model 3D thin structures. Findings Via the VUEL user-element subroutines, the performance of these elements is assessed through a set of selective and representative dynamic elastoplastic benchmark tests, impact-type problems and deep drawing processes involving complex non-linear loading paths, anisotropic plasticity and double-sided contact. The obtained numerical results demonstrate good performance of the SHB-EXP elements in the modeling of 3D thin structures, with only a single element layer and few integration points in the thickness direction. Originality/value The extension of the SHB-EXP solid-shell formulations to large-strain anisotropic plasticity enlarges their application range to a wide variety of dynamic elastoplastic problems and sheet metal forming simulations. All simulation results reveal that the numerical strategy adopted in this paper can efficiently prevent the various locking phenomena that commonly occur in the 3D modeling of thin structural problems.