Development of Quasi Two-Dimensional FEM Model for Boss-Forming Analysis

Abstract

A rotary forming analysis model generally needs massive elements for solving large plastic deformation of three- dimensional problems with sufficient accuracy. Beforehand, we developed a compact form-rolling analysis model composed of small hoop-angle one-layer solid elements given a certain angular-velocity field. We have also developed a boss-forming analysis model with a unique extention of the above-mentioned method. This model can be used to analyze stress concentration with enough precision near the contact area between the roll and the blank. The computation time of the model was less than 1/1000 of that when using the full-scaled model. Our model will shorten both the modeling time and the model refining time in the early design stage of products prepared by the boss-forming production process.