Abstract
A finite element simulation of flexible bulge forming of aluminum sheet metal is carried out. The effect of rubber pad on forming capability is studied by comparing flexible bulge to hydroforming. Based on the theory of Continuum Damage Mechanics (CDM), a local approach with fully coupling between ductile damage and an anisotropic elasto-plastic model with mixed nonlinear kinematic/isotropic hardening is introduced. The model is implemented into a user-defined material (VUMAT) subroutine for the commercial finite element code ABAQUS/Explicit. A Mooney-Rivlin theory is adopted for rubber material behavior. Comparisons between both processes in terms of thickness variation, damage occurrence, and sheet formability are conducted for different rubber shores and friction. Numerical findings are in a good correlation with experiments from literature.
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