NUMISHEET 2014 Benchmark #1 Nonlinear Strain Path Forming Limit Prediction of a Reverse Draw

Changqing Du - Chrysler Lianxiang Yang - Oakland University Xin Wu Wayne State University Ming F. Shi - United States Steel Corporation Gang Huang ArcelorMittal, Global R&D Tom Stoughton - GM

NUMISHEET 2014 Benchmark #1 Forming Limits of a Reverse Draw

Objective: Demonstrate the predictability capability on forming limits for a draw panel with a non-axisymmetric reversed dome-shape at the center at different strain paths. Scopes: (1) Simulate the preform process, Die-1. This process is to prepare the pre-formed samples with draw-bead geometry for the subsequent reverse draw process, Die-2. (2) Simulate the reverse draw process, Die-2,
- Task 1: To predict the location or locations where the onset necking occurs and their corresponding limit strain. - Task 2: To predict the strain path at specified locations and major and minor strains distributions along the specified sections at a given forming depth

Material: M-1: AA5182-O M-2: DP600 M-3: TRIP780

1.1 mm Thickness 1.0 mm Thickness 1.0 mm Thickness

Reverse-Draw Die
Die-1: Preform
Form a draw-bead to the blank to prepare the initial blank for Die 2

Die-2:
Use the blank with a draw bead from Die-1 as the initial blank Blank clamping is manually applied by tightening 15 equal spacing bolts with 190 N-M Torque per bolt. The height of the insert dome can be adjusted by shimming

Die-1 Panel

the plates between insert and lower die base

Reverse Draw Panel

Reverse Draw Die Set

Upper Die Axisymmetric

Lower Insert Dome Non-Axisymmetric

Material data provided

Mechanical data:
sy0, sy45, sy90, r0, r45, r90, and other data (i.e. sb & rb if available)

Hardening curve:
Uniaxial true stress-true strain up to max load at 0, 45, 90
(note this is raw data unsmoothed, with serrated flow)

Friction data:
- Lab measurement data or references

Forming Limit data:

- Conventional Forming limit curve in the strain space (proportional strain path)

Blank size and die dimensions

- Blank shapes defined in IGES format and common orientation of the RD to the die

Blank clamping force

- Binder clamping is manually applied by tightening 15 equal spaced bolts with 190 N-M Torque per bolt.

Results Required
Task 1: Forming limit strain prediction Location or locations where the onset necking can be detected Major and minor strains of the point or points where the onset necking can be detected Task 2: Strain path prediction Major and minor Strain histories at the specified locations from beginning to the specified forming depth Major and minor strain distributions along the specified locations at a given forming depth Option: Punch load vs. forming depth up to the given depth