The S-Rail part has become a standard benchmark for testing finite element simulation
codes in stamping operations. This medium size problem (3000 shell elements) is often used
as an industrial benchmark to verify the numerical procedures employed.
In our simulation, the tools are modeled using rigid elements as shown in the figure above. The punch is shown in red, the blank holder in green, and the die in blue. The sheet metal (cyan color) is modeled with 4-node shell elements.
The combination of strong technologies in ADINA, such as high performance elements, implicit static and dynamic time integration, and accurate contact algorithm allows such problems to be analyzed with good accuracy.
Through the simulation results, the development of the plastic regions can be analyzed. The above animation shows the band plots of the accumulative effective plastic strain obtained using ADINA.
This animation includes the results of springback in the ADINA simulation. Note the increasing stresses in the part from start to time 1.0. After that, the stresses start to decrease as a result of the springback. The final shape after the springback is obtained at time 1.5.
We would like to highlight that the solution time for the springback simulation is less than 10% of the stamping simulation time. This percentage is typical for most metal forming simulations using ADINA.