Metal Forming Similarity Theory in Numerical Simulations

In the development of new metal forming procedures, it is crucial to understand process parameters such as forming force, deformation work, and stress schemes. Theoretical analysis often falls short due to numerous simplifications and assumed boundary conditions that fail to accurately depict real-world scenarios. In addition to numerical simulations, physical modeling by scaling real dimensions offers a superior method. Similarity theory serves as a bridge between the model, real product, and process parameters. This paper explores the integration of finite element modeling with similarity theory to efficiently determine the forming force levels for real products. A numerical model is created and validated through both similarity theory and finite element modeling.