Simulation of sheet metal forming using explicit finite-element techniques: effect of material and forming characteristics: Part 1. Deep-drawing of cylindrical cups

Abstract

The use of the explicit non-linear finite element (FE) code DYNA 3D in sheet metal forming simulation is examined. A 3D FE model for the deep-drawing of cylindrical cups was constructed and the simulation results obtained using different simulation parameters, i.e. punch velocity, sheet material density, Coulomb friction coefficient at the tool–blank interfaces and type and dimensions of the FE mesh-elements, compared with experimental results regarding strain distributions (radial, circumferential and thickness through the sheet) and punch force–punch travel curves carried out on five galvanised steels and an aluminium sheet, for three different geometries of axisymmetric cup: Good agreement was obtained. The evaluation of the CPU time cost, the macroscopic deformation modes, the strain distributions of the deformed material and the process characteristics obtained for the constructed FE models, was directed towards the selection of the most efficient material and punch parameters. Finally, an attempt was made to construct rules from the above-mentioned verification, which may be used for reliable sheet metal forming simulations, using explicit finite-element codes.