An improved FEM-DEM coupling simulation for granular-media-based thin-wall elbow tube push-bending process

The granular-media-based push-bending process has been developed to manufacture thin-wall elbow tube with t/D≤0.01 (the ratio of wall thickness to outer diameter) and R/D≤1.5 (the ratio of bending radius to outer diameter). In the process, a tubular blank is filled with granular media and then pushed into a die to form an elbow shape. To investigate the process, a FEM-DEM coupling model has been developed, in which FEM is used to simulate bending deformation of tubular blank, and DEM is used to calculate contact forces between spherical particles in granular media. In this work, an improved numerical formulation is proposed in order to reach mechanical equilibrium quickly and accelerate the convergence of DEM simulation, when the new contacts are no longer created and the old contacts are no longer deleted in granular media. Using the proposed numerical formulation, the improved FEM-DEM coupling simulation for granular-media-based thin-wall elbow tube push-bending process is less time-consuming than before under the same simulation condition.