Selective proper orthogonal decomposition model reduction for forming simulations

Abstract

Robot‐based incremental sheet metal forming is a cost‐effective and flexible method for prototype and low batch size production. The simulation of such processes is very challenging and elaborate from the computational point of view. To reduce the computational effort model reduction techniques such as proper orthogonal decomposition (POD) can be applied. But the reduction of highly non‐linear models in solid mechanics for example forming simulation still leads to problems of efficiency and accuracy. Therefore, the aim of this paper is to present an alternative way to use POD for forming processes. The presented selective POD (SPOD) method is used to split the model into two domains depending on the degree of plastic strain. Only the domain with approximately linear elastic behavior will be reduced by using POD. Utilizing the SPOD method for the example of forming a horizontal flute reduces the computational time up to around 30 per cent. High accuracy with approximation errors smaller than one per mill is achieved. (© 2013 Wiley‐VCH Verlag GmbH & Co. KGaA, Weinheim)