Validation of material models for sheet metals using new test equipment

Abstract

Validation is an important step after a calibration of models in order to assess their quality. In this work, new test equipment is presented that provides a comprehensive database for validation of material models for numerical analyses using FE simulation in sheet metal forming: the MUC-Test (acronym for Material Under Control). The introduced validation strategy is based on a comparison of experimental results with a numerical representation of the MUC-Test in terms of punch force and major and minor strain. The data comparison approach uses a full-field comparison over a wide range of punch stroke and thus considers the hardening behavior of the models. Extensive parameter studies are performed to investigate numerical, process and material model parameters regarding their influence on the test results. The presented validation method is applied to three materials of different material classes: The microalloyed steel HC340LA, the dual-phase steel DP590HD and the aluminum alloy AA5754. Furthermore, different material models based on the same database are compared for the DP590HD, showing the potential to identify suitable material models for specific requirements. Finally, equivalent material models based on different calibration strategies are compared. In conclusion, it is shown that the MUC-Test can be used to evaluate and compare different material models in terms of their ability to represent real material behavior in an effective and efficient way.