ABSTRACT
In order to fully realize the strength potential of cold-formed parts, strain hardening and residual stress from the cold-forming process must be considered in structural FEA simulations of the loaded condition. However, only topological data have previously been transferred when using separate forming and structural-simulation tools. This paper presents a new method for transferring local residual stress and strain data from the forming simulation tool Deform3D TM to the structural analysis toolAnsysWorkbench. The aim of the method is to increase the accuracy of structural-simulation results for cold-formed parts under load using separate simulation tools for the cold-forming and structural behaviour of manufactured components. The application of the method is demonstrated using the example of a full-forward-extruded shaft under torsional load. Validation of the data transfer and comparison of simulated deformation behaviour of the shaft, both including and discarding residual stress and strain, are carried out.
