Solid vs Shell: Thickening

Huge difference in contact behaviour between shell and solid

A typical situation in sheet metal forming is the compression of the thickened zones of the sheet when the press closes. Within this event material is compressed with a lot of force resulting in huge and uncontrolled stresses that have massive consequences for the springback behavior. However, due to non-physical contact shell simulation fails to show compression due to contact pressure.

Hence, we always recommend:

✔   Use solid simulation to get realistic thickness results in zones with compression

✔   Use solid simulation for an excellent springback prediction in parts that have thickened zones.

In the video above you see a typical progressive die example that shows the different contact behaviour between shell and solid simulation in a real-world example.