Sectional finite element analysis of forming processes for aluminum-alloy sheet metals

Abstract The sectional finite element analysis of the forming processes for the aluminum-alloy sheet metal known to be planar anisotropic was performed. The two-dimensional rigid-viscoplastic FEM formulation based on the bending augmented membrane theory as well as the anisotropic yield criteria was introduced. For modeling the anomalous behavior of aluminum-alloy sheet metals, Barlat's strain rate potential and Hill's (Journal of the Mechanics and Physics of Solids 1990;38:405–17) non-quadratic yield theory with an isotropic hardening rule were employed. Furthermore, a new method to determine anisotropic coefficients of Barlat's strain rate potential was proposed. For evaluating bending effects in the forming process of aluminum-alloy sheet metals, the bending equivalent forces were calculated in terms of the changes in the interior angle at a node between two linear finite elements and were augmented to the membrane stretch forces. In order to verify the validity of sectional finite element formulation based on the bending augmented membrane theory, the plane strain stretch/draw forming processes of a square cup test were simulated and simulation results are compared with experimental measurements. Friction coefficient was obtained from drawbead friction test. The properties of selected material were obtained from uniaxial tensile tests. Simulation shows good agreement with measurements. For the application of the sectional finite element formulation introduced in this research, the drawing process of a rear seat back upper bracket of passenger cars is simulated assuming plane strain condition. The thinning distribution of the simulation agreed well with that of the measurement, so that the sectional analysis is acceptable in the design and analysis of aluminum-alloy sheet stamping dies.