Abstract
This study was performed to analyze the forming fracture of crash box with extruded Al6060-T6 profile. Deep drawing test was performed to evaluate the formability of the extruded profile. For the various specimens, deep drawing tests were repeated to measure the maximum stroke at which fracture did not occur. The finite element analysis for the deep drawing tests was performed to calculate the principal strain through the obtained maximum stroke. The forming limit diagram for the design of the concave forming shape was calculated through the obtained principal strains with the FEA. The forming shape was optimized by using the design variables and FLD by using the FEA. The design variables are the central curvature, the lateral curvature, and the forming depth. The tools were made with the optimizing model and the crash box has been formed without fracture.
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