An accurate-optimized mesh for thermo-mechanical analysis of laser forming process

Abstract

Laser forming process is used to form metal sheets in more or less complex three-dimensional shapes with good results for small-medium series or prototypes for its remarkable flexibility and precision and for no-dies need. The process is not yet well understood and for this purpose finite element analysis is a good and cheap tool. However numerical analysis can results time expensive for complexity related to this process, modelled as a thermo-mechanical coupled problem, characterized by remarkable geometric and material nonlinearity, to convective-radiative boundary conditions and Gaussian power density distribution in laser beam spot. In this paper a 3D finite element model for laser forming is proposed with an accurate-optimized mesh in order to obtain good accuracy and to reduce computational time. The influence of spot movements simulation is also considered. Numerical results are compared with experimental data.