Non-Uniform Effect of the Contact Conditions on the Earing Profile in Cylindrical Cups of Anisotropic Materials

Abstract

The earing profile of cylindrical cups is mainly dictated by the in-plane anisotropic behavior of the metal sheet. Nevertheless, for materials with a strong anisotropic behavior the contact conditions between the blank and the blank-holder can also affect the material flow due to the non-uniform distribution of the contact forces. The main objective of this study is to numerically assess the influence of the friction conditions on the cup earing profile using the AA3104 aluminum alloy. The strong anisotropy of the r-values of this material leads to a non-uniform thickness distribution along the circumferential direction of the flange, resulting in increased thickening in the transverse direction. The effect of the friction coefficient on the earing profile is approximately 4 times larger in the transverse direction than in the rolling direction.