Sheet metal forming analyses with an emphasis on the springback deformation

Abstract An accurate modeling of the sheet metal deformations including the springback is one of the key factors in the efficient utilization of FE process simulation in the industrial setting. In this paper, a rate-independent anisotropic plasticity model accounting the Bauschinger effect is presented and applied in the FE forming and springback analyses. The proposed model uses the Hill's quadratic yield function in the description of the anisotropic yield loci of planar and transversely anisotropic sheets. The material strain-hardening behavior is simulated by an additive backstress form of the nonlinear kinematic hardening rule and the model parameters are computed explicitly based on the stress–strain curve in the sheet rolling direction. The proposed model is employed in the FE analysis of Numisheet’93 U-channel benchmark, and a performance comparison in terms of the predicted springback indicated an enhanced correlation with the average of measurements. In addition, the stamping analyses of an automotive part are conducted, and comparisons of the FE results using both the isotropic hardening plasticity model and the proposed model are presented in terms of the calculated strain, thickness, residual stress and bending moment distributions. It is observed that both models produce similar strain and thickness predictions; however, there appeared to be significant differences in computed residual stress and bending moments. Furthermore, the springback deformations with both plasticity models are compared with CMM measurements of the manufactured parts. The final part geometry and overall springback distortion pattern produced by the proposed model is mostly in agreement with the measurements and more accurate.