Modeling and Simulation of the Forming of Aluminum Sheet Alloys

Abstract

WITH ADVANCES in computer hardware and software, it is possible to model material processing, product manufacturing, product performance in service, and failure. Although the fine-tuning of product manufacturing and performance is empirical, modeling can be an efficient tool to guide and optimize design, to evaluate material attributes, and to predict lifetime and failure. Moreover, modeling can be used as a research tool for a more fundamental understanding of physical phenomena that can result in the development of improved or new products. This article is concerned with the numerical simulation of the forming of aluminum alloy sheet metals. The mathematical descriptions of material behavior, are material-specific. Therefore, macroscopic and microscopic aspects of the plastic behavior of aluminum alloys are reviewed first: ´ Constitutive equations suitable for the description of aluminum alloy sheets ´ Testing procedures and analysis methods used to measure the relevant data needed to identify the material coefficients ´ Tensile and compressive instabilities in sheet forming. For tensile instability, both strain- and stress-based forming-limit curves are discussed. ´ Springback analysis ´ Finite Element (FE) formulation ´ Stress-integration procedures for both continuum and crystal-plasticity mechanics ´ Finite element design Finally, various examples of the simulation of aluminum sheet forming are presented. These examples include earing in cup drawing, wrinkling, automotive stamping, hemming, hydroforming, and clam-shell-resistant design via FE analysis and the Taguchi (Ref) optimization method. 6061-T4 tubes used as example in two models shown in two figures. Nothing in the text related to 6061.