Homogenisation of the strain distribution in stretch formed parts to improve part properties

Abstract

Inhomogeneous strain and sheet thickness distributions can be observed in complex sheet metal parts manufactured by stretch forming. In literature, this problem is solved by flexible clampings adapted to the part geometry. In this paper, an approach, which does not rely on extensive tooling, is presented. The strain distribution in the sheet is influenced by means of hole patterns. Holes are introduced into the sheet area between clamping and part next to areas where high strains are expected. When deforming the sheet, high strains are shifted out of the part area. In a local area around the holes, high strains concentrate perpendicular to the drawing direction. Thus, high strains in the part area are reduced and the strain distribution is homogenised. To verify this approach, an FE-model of a stretch forming process of a conical part is implemented in LS-Dyna. The model is validated by corresponding experiments. In the first step, the positioning of the holes is applied manually based on the numerically determined strain distribution and experience. In order to automate the positioning of the holes, an optimisation method is applied in a second step. The presented approach implemented in LS-OPT uses the response surface method to identify the positioning and radius of the holes homogenising the strain in a defined area of the sheet. Due to nonlinear increase of computational complexity with increasing number of holes, the maximum number of holes is set to three. With both, the manual and the automated method, hole patterns were found which allow for a relative reduction of maximum strains and for a homogenisation of the strain distribution. Comparing the manual and automated positioning of holes, the pattern determined by automated optimisation shows better results in terms of homogenising the strain distribution.