Deep drawing simulations using the finite element method embedding a multi-level crystal plasticity constitutive law: Experimental verification and sensitivity analysis.

This paper presents experimental verification of a multi-level simulation framework aimed at sheet metal forming analysis. Specifically, deep drawing of a cylindrical cup simulations from alloy AA6022-T4 sheets are carried out using a physically based elasto-plastic self-consistent (EPSC) polycrystalline homogenization model embedded in implicit finite elements and verified experimentally. The EPSC model takes into account the evolution of microstructure and directionality of deformation mechanisms acting at the single-crystal level in predicting material behavior. It is calibrated and validated as a standalone model using flow stress and R-ratio data as well as iso-shear contours measured along several directions of the sheet through uniaxial and plane strain tension experiments. Furthermore, the particularities pertaining to cyclic response including non-linear unloading and the Bauschinger effect are also calibrated through large strain tension–compression data. Consistent with experimental measurements, the process simulations in finite elements predict directionally dependent thinning of the cup, especially around the punch radius and variation in the cup height around the rim of the cup, referred to as earing. By comparing experiments and predictions, role of the R-ratio is revealed as critical for the accurate prediction of the cup height. Further sensitivity analysis shows that initial texture has a strong influence on the R-ratio, while introducing a minor effect on hardening. The analysis into the choice of finite element types in terms of their accuracy and efficiency shows that the 3D 8 nodal elements (C3D8R) and continuum shell 3D 8 nodal elements (SC8R) are superior over the planar shell 3D 4 nodal elements (S4R) with the former being the most accurate and the latter being computationally efficient. It is demonstrated that the simulation framework presented in this paper can be used to predict phenomena pertaining to material behavior and resulting geometrical changes important for optimization of the sheet metal forming processes. • Grain-to-polycrystal-to-component level models are linked to simulate cup drawing. • Hardening, unloading, Bauschinger effect, and geometrical changes are predicted. • Crystallographic texture is found to govern R-ratio. • Role of R-ratio in predicting cup height is explained. • Continuum 3D elements are recommended for crystal plasticity sheet metal forming. [ABSTRACT FROM AUTHOR]