Influence of Drawbeads in Deep-Drawing of Plane-Strain Channel Sections: Experimental and FE Analysis
- CEMUC, Department of Mechanical Engineering, University of Coimbra, Polo II, Rua Luis Reis Santos, Pinhal de Marrocos, 3030-788 Coimbra (Portugal)
- Department of Mechanical Engineering, University of Minho, Campus de Azurem, 4800-058 Guimaraes (Portugal)
- Department of Mechanical, Automotive and Materials Engineering, University of Windsor, Windsor, Ontario, N9B 3P4 (Canada)
The main purpose of the 'Numisheet'05 Benchmark no. 3: Channel Draw/Cylindrical Cup' was to evaluate the forming characteristics of materials in multi-stage processes. The concept was to verify the strain fields achieved during the two stage forming process and also to test the ability of numerical models to predict both strain and stress fields. The first stage consisted of forming channel sections in an industrial-scale channel draw die. The material that flows through the drawbead and over the die radii into the channel sidewalls is prestrained by cyclic bending and unbending. The prestrained channel sidewalls are subsequently cut and subjected to near plane-strain Marciniak-style cup test. This study emphasizes the analysis of the first stage process, the Channel Draw, since accurate numerical results for the first stage forming and springback are essential to guarantee proper initial state variables for the subsequent stage simulation. Four different sheet materials were selected: mild steel AKDQ-HDG, high strength steel HSLA-HDG, dual phase steel DP600-HDG and an aluminium alloy AA6022-T43. The four sheet materials were formed in the same channel draw die, but with drawbead penetrations of 25%, 50% and 100%. This paper describes the testing and measurement procedures for the numerical simulation of these conditions with DD3IMP FE code. A comparison between experimental and numerical simulation results for the first stage is presented. The experimental results indicate that an increase in drawbead penetration is accompanied by a general decrease in springback, with both sidewall radius of curvature and the sidewall angle increasing with increasing drawbead penetration. An exception to this trend occurs at the shallowest bead penetration: the radius of curvature in the sidewall is larger than expected. The sequence of cyclic tension and compression is numerically studied for each drawbead penetration in order to investigate this phenomenon.
- OSTI ID:
- 21061766
- Journal Information:
- AIP Conference Proceedings, Vol. 908, Issue 1; Conference: NUMIFORM 2007: 9. international conference on numerical methods in industrial forming processes, Porto (Portugal), 17-21 Jun 2007; Other Information: DOI: 10.1063/1.2740915; (c) 2007 American Institute of Physics; Country of input: International Atomic Energy Agency (IAEA); ISSN 0094-243X
- Country of Publication:
- United States
- Language:
- English
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