Sensitivity analysis on an AC600 aluminum skin component

Abstract

New materials are been introduced on the car body in order to reduce weight and fulfil the international CO2 emission regulations. Among them, the application of aluminum alloys is increasing for skin panels. Even if these alloys are beneficial for the car design, the manufacturing of these components become more complex. In this regard, numerical simulations have become a necessary tool for die designers. There are multiple factors affecting the accuracy of these simulations e.g. hardening, anisotropy, lubrication, elastic behavior. Numerous studies have been conducted in the last years on high strength steels component stamping and on developing new anisotropic models for aluminum cup drawings. However, the impact of the correct modelling on the latest aluminums for the manufacturing of skin panels has been not yet analyzed. In this work, first, the new AC600 aluminum alloy of JLR-Novelis is characterized for anisotropy, kinematic hardening, friction coefficient, elastic behavior. Next, a sensitivity analysis is conducted on the simulation of a U channel (with drawbeads). Then, the numerical an experimental results are correlated in terms of springback and failure. Finally, some conclusions are drawn.