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The main goal of this work is to determine the influence of the work hardening model in the numerical prediction of springback. This study will be performed according with the specifications of the first phase of the “Benchmark 3” of the Numisheet’2005 Conference: the “Channel Draw”. Several work hardening constitutive models are used in order to allow a better description of the different material mechanical behavior. Two are classical pure isotropic hardening models described by a power law (Swift) or a Voce type saturation equation. Those two models were also combined with a non-linear (Lemai⁁tre and Chaboche) kinematic hardening rule. The final one is the Teodosiu microstructural hardening model. The study is performed for two commonly used steels of the automotive industry: mild (DC06) and dual phase (DP600) steels. The mechanical characterization, as well as the constitutive parameters identification of each work hardening models, was performed by LPMTM, based on an appropriate set of experimental data such as uniaxial tensile tests, monotonic and Bauschinger simple shear tests and orthogonal strain path tests, all at various orientations with respect to the rolling direction. All the simulations were carried out with the CEMUC’s home code DD3IMP (contraction of ‘Deep Drawing 3-D IMPlicit code’). © 2005 American Institute of Physics [ABSTRACT FROM AUTHOR]

Advanced high strength steels (AHSS) are increasingly being used in the automotive industry to reduce vehicle weight while improving vehicle crash performance. One of the concerns in manufacturing is springback control after stamping. Although computer simulation technologies have been successfully applied to predict stamping formability, they still face major challenges in springback prediction, particularly for AHSS. Springback analysis is very complicated and involves large deformation problems in the forming stage and mechanical multiplying effect during the elastic recovery after releasing a part from the die. Therefore, the predictions are very sensitive to the simulation parameters used. It is very critical in springback simulation to choose an appropriate material model, element formulation and contact algorithm. In this study, a springback benchmark test, the slit ring cup, is used in the springback simulation with commercially available finite element analysis (FEA) software, LS-DYNA. The sensitivity of seven simulation variables on springback predictions was investigated, and a set of parameters with stable simulation results was identified. Final simulations using the selected set of parameters were conducted on six different materials including two AHSS steels, two conventional high strength steels, one mild steel and an aluminum alloy. The simulation results are compared with experimental measurements for all six materials and a favorable result is achieved. Simulation errors as compared against test results falls within 10%. © 2005 American Institute of Physics [ABSTRACT FROM AUTHOR]

Sheet metal forming software is commonly used in the automotive and sheet metal sectors to support the design stage. However, the ability of the currently available software to accurately predict springback is limited. A sensitivity analysis of the springback behavior of a simple product is performed to gain more knowledge into the various factors contributing to the predictability of springback. The sensitivity analysis comprises both numerical and physical aspects and the most important results are reported in this paper. © 2005 American Institute of Physics [ABSTRACT FROM AUTHOR]

Prediction of formability for sheet metal pressings has advanced to a high state of confidence in recent years. The major challenge is now to predict springback and, moreover, to assist in the design of tooling to correctly compensate for springback. This is particularly the case for materials now being routinely considered for automotive production, such as aluminium and ultra high strength steels, which are prone to greater degrees of springback than traditional mild steels. This paper presents a case study based on the tool design for an ultra high strength steel side impact beam. The forming and springback simulations, carried out using eta/DYNAFORM (based on the LS-DYNA solver), are reported and compared to measurements from the prototype panels. The analysis parameters used in the simulation are presented, and the sensitivity of the results to variation in physical properties is also reviewed. The process of compensating the tools based on the analysis prediction is described; finally, an automated springback compensation method is also applied and the results compared with the final tool design. © 2005 American Institute of Physics [ABSTRACT FROM AUTHOR]

Stretch bending is commonly used to shape thin-walled extrusions in aerospace and automotive industries. The extrusions are pre-stretched and bent over rigid curved dies. Effective application of this process demands sufficient knowledge of how different parameters influence the final shape of the product. Numerical simulation is an effective approach to investigate these issues presently. However, the validity of simulation result depends strongly on a precise description of the mechanical behavior of the material. Due to crystallographic texture caused by the extrusion process, aluminium extrusions exhibit significant plastic anisotropy which need be described by advanced constitutive model. In this work stretch bending of aluminum extrusions is simulated by using different anisotropic criteria (Hill quadratic, Barlat three-parameter). The influence of two yield criteria on predicting maximum die force immediately before unloading, permanent sagging and vertical springback displacement in the middle section of extrusion are compared. Maximum die force and springback calculated by two yield criteria are found to be almost same. Permanent sagging is obviously underestimated by two yield criteria, however, prediction by Barlat three-parameter is closer to experiment than one of Hill quadratic yield criterion. © 2005 American Institute of Physics [ABSTRACT FROM AUTHOR]

Commodity thermoplastics such as polypropylene and polyethylene are gaining more attention from the automotive industries for applications requiring weight and cost savings. In order to assess the feasibility of employing thermoplastic tubes for subsequent forming into automotive structural components, first an establishment of the forming limits (or the forming limit diagram) for these materials is required. An analytical model, which is able to predict the forming limits for thermoplastic tubes, is useful from the perspective of examining the effect of material properties on the forming of a given shape without numerous experimental forming trials. Knowledge of the forming limits for these materials is also useful in die design as well as process control. Since thermoplastics such as polypropylene are temperature and strain rate dependent, the proposed analytical model would be able to predict the effect of temperature and strain rate on the resulting forming limits for the tube along various loading paths. Preliminary results from the model indicate that thermoplastic tubes formed at elevated temperature undergo larger strains in both the hoop and axial directions of the tube prior to localized necking. © 2005 American Institute of Physics [ABSTRACT FROM AUTHOR]

Line die forming simulation and validation create tremendous business values for automotive die developments and production stamping while they pose a great technological challenge to stamping CAE community. GM Manufacturing Engineering Die Center has developed an integrated line die analysis technology to validate die lines as a productionized business process. In this process, a finished stamping body panel can be streamline analyzed with required time, accuracy, and quality. This paper presents critical issues in line die analysis, discusses technical challenges in production applications and software development, and finally demonstrates the impact of line die forming simulation and validations on automotive body styling and tooling developments. © 2005 American Institute of Physics [ABSTRACT FROM AUTHOR]

The punchless piercing is a process that uses highly pressurized fluid instead of the conventional punch to make holes into the sheet metal. This process has many advantages over the conventional method for piercing various shaped holes into very thin strips of metal, composite, etc. An important cost advantage comes from not having to use a punch. Another important advantage comes from the top quality of pierced holes produced by punchless piercing, as no secondary finishing process will be needed for removing burrs typically found in conventional cutting processes. The ABAQUS/Explicit FEM code coupled with Lemaitre damage model has been used to more precisely characterize the punchless piercing process. The formulation adopted for this purpose focuses on the development of an efficient stress integration algorithm and development of a user material subroutine (VUMAT). For verification, the computed results have been compared with those of the experimental results in the literature and shown to be in good agreement with each other. The results obtained from this work are expected to be of significant interest to automotive and aerospace industries interested in using the punchless piercing process. © 2005 American Institute of Physics [ABSTRACT FROM AUTHOR]

In comparison to the commonly applied technology of tailored blanks the concept of patchwork blanks offers a number of additional advantages. Potential application areas for patchwork blanks in automotive industry are e.g. local reinforcements of automotive closures, structural reinforcements of rails and pillars as well as shock towers. But even if there is a significant application potential for patchwork blanks in automobile production, industrial realization of this innovative technique is decelerated due to a lack of knowledge regarding the forming behavior and the numerical modeling of patchwork blanks. Especially for the numerical simulation of hydroforming processes, where one part of the forming tool is replaced by a fluid under pressure, advanced modeling techniques are required to ensure an accurate prediction of the blanks’ forming behavior. The objective of this contribution is to provide an appropriate model for the numerical simulation of patchwork blanks’ forming processes. Therefore, different finite element modeling techniques for patchwork blanks are presented. In addition to basic shell element models a combined finite element model consisting of shell and solid elements is defined. Special emphasis is placed on the modeling of the weld seam. For this purpose the local mechanical properties of the weld metal, which have been determined by means of Martens-hardness measurements and uniaxial tensile tests, are integrated in the finite element models. The results obtained from the numerical simulations are compared to experimental data from a hydraulic bulge test. In this context the focus is laid on laser- and spot-welded patchwork blanks. © 2005 American Institute of Physics [ABSTRACT FROM AUTHOR]