Simulation of sheet metal forming by a one-step approach: choice of element

Based on a one-step simulation algorithm and the program developed, a new finite element approach is introduced for the direct prediction of blank shapes and strain distributions for desired final shapes in sheet metal forming. In the numerical simulation, the choice of optimal element plays an important role and is related to the accuracy and effectiveness of solving the problems. Since a one-step approach needs to predict the initial blank shape and the thickness distribution in a deformed part rapidly, the application of the DKT shell element including bending effects is preferable because of its simplicity and effectiveness. As a result, new and compact formulations of this element are given in this paper. Formulations of a one-step simulation are also revised. Results from the deep drawing of square and cylindrical cups using the DKT shell and membrane element are compared with the available experimental data.