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Mert ÖZDOĞAN, Hatice SANDALLI YILDIZ
A CASE STUDY OF THE EFFECT OF ELEMENT TYPE ON THE NUMERICAL SIMULATION RESULTS OF FASTENER COLD FORGING PRODUCTION
 
Finite element solution of any mathematical model requires discrete finite elements(FE) or mesh, and accuracy of finite element analysis(FEA) significantly depends on it.. Increasing the element count, in most cases, improves the accuracy of FEA, but it yields to a higher computational power. Altering the order of shape functions or elements degrees of freedom(DOF) is another approach to achieve decent accuracy with less element count, but, it is crucial to choose right element type in order to get real-like physical results. In this study, FE with various DOF are examined for deformation process of hexagon weld nut. FE analysis are conducted on Simufact.Forming for mesh types with increasing DOF; tetrahedral(134), tetrahedral(157) and tetrahedral(247), in order to investigate the effect of element type on cold forging simulation. Results are compared with hexahedral mesh, which is recommended element type by Simufact, for effective plastic strain, contact pressure, geometrical accuracy and required forging power. It is found that for equal element count, geometry is almost same for all tetrahedral types and they are similar to hexahedral mesh. Tetrahedral(134) results found to be disproportional in the sense of plastic strain and contact pressure, compared to reference mesh and should be avoided for current case. Tetrahedral(157) and tetrahedral(247) yield to similar results but the latter can compute quadruply faster and its results are more similar to hexahedral mesh. Correlation between DOF and FEM accuracy is observed. It is suggested that for such plastic deformation problem, elements with high DOF is found to be more convenient. ORCID NO: 0000-0001-8229-0563, 0000-0002-5550-8480

Anahtar Kelimeler: Finite Element Analysis, Degree of Freedom, Cold Forging Simulation, Mesh Type



 


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