Int J Adv Manuf Technol (2011) 54:113121 DOI 10.

1007/s00170-010-2931-9

ORIGINAL ARTICLE

Experimental and finite element investigation on wrinkling of circular single layer and two-layer sheet metals in deep drawing process
Mohammad Reza Morovvati & Afshin Fatemi & Mojtaba Sadighi

Received: 11 July 2009 / Accepted: 6 September 2010 / Published online: 30 September 2010 # Springer-Verlag London Limited 2010

Abstract This paper deals with the comparison of wrinkling behavior of both single and two-layer sheets in the deep drawing process. Unfortunately, due to the significant difference in the material properties of the two layers, it is very challenging for the finite element method to predict the location and relative possibility of wrinkling in the multilayer sheets. Blank holder force (BHF) has a significant effect on the failure mode of sheet metals. By decreasing BHF, wrinkling turns out as the principal failure mode, whereas its increase results in splitting and fracture. Thus, this paper investigates the effect of blank holder forces on wrinkling and fractures in drawing process of single and two layers. Moreover, the effect of material and arrangement of layers on wrinkling, fracture, and required deformation forces in the cylindrical deep drawing will be discussed. Results show that the optimum blank holder force for two-layer sheets is affected by the material and arrangements of lay-ups. Keywords Two-layer sheet . Wrinkling . Fracture . Deep drawing . FEM . BHF

1 Introduction In the recent years, two-layer sheets due to their superior corrosion resistance and different electrical conductivity of each layer are increasingly used in the aerospace and automobile industry [1, 2]. Nowadays, in two-layer steel/ aluminum and steel/copper sheets for automotive and
M. R. Morovvati (*) : A. Fatemi : M. Sadighi Mechanical Engineering Department, Amirkabir University of Technology, Tehran, Iran e-mail: reza.morovvati@aut.ac.ir

aerospace applications in the deep drawing, the quality of the formed part is affected by the amount of metal drawn into the die cavity. Excessive metal flow will cause wrinkles in the part, while insufficient metal flow will result in tears or splits. The blank holder plays a key role in regulating the metal flow by exerting a predefined blank holder force (BHF) profile. When selected properly, this BHF profile can eliminate wrinkles and delay fracture in the drawn sheet. There have been many attempts to obtain the minimum blank holding pressure that prevents wrinkling. Senior [3] has evaluated the energy terms that are responsible for causing wrinkles (due to membrane stresses) and suppressing wrinkles (due to buckling and blank holder pressure), considering the material to be isotropic with constant sheet thickness. Triantafyllidis and Needleman [4] studied the influence of blank holder stiffness on wrinkling behavior using elastoplastic finite element analysis (FEA) approach, modeling the flange as an annular plate subjected to axisymmetrical radial tension along its inner edge. They also incorporated the effect of transverse anisotropy on the wrinkling behavior. Yu and Johnson [5] studied the effect of blank holder pressure on the buckling behavior of the flange. In their work, strain energy of bending in plastic buckling is equated with the work done by the in-plane stresses (membrane stresses) to get the critical condition for wrinkling. Amziane-Hassani and Neale [6] analyzed the wrinkling by bifurcation theory and investigated the effect of material properties and blank geometry on wrinkling behavior. Since 1991, many research efforts have been dedicated to study wrinkling in homogenous metallic sheets such as Yung and Lee [7], Sukhomlinov et al. [8], Kampus and Kuzman [9], and Wang et al. [10]. Mori and Kurimoto [11] investigated forming of stainless steel and aluminum clad sheet. They carried out tensile test on clad sheet as well

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as its element to determine fundamental mechanical properties. They argued that factors related to deformation, such as wrinkling and cup height, are controlled by higher strength portion. Also, they reported that fracture mechanism is related to thickness strain. Zeng and Mahdavian [12] studied the effect of temperature on the critical condition for wrinkling. Buckling moment due to the hoop stress, moment due to resistance to bending deflection, moment due to blank holder force, and moment induced at the die radius were considered for predicting critical condition for wrinkling, assuming the material to be isotropic with constant sheet thickness. Parsa et al. [13] observed drawing and redrawing of two-layer aluminum stainless steel sheet through FEA and experiments. Cao et al. [14] designed a novel wedge strip test, which simulated various boundary conditions in forming processes where wrinkles would initiate. Cheng et al. [15] investigated wrinkling behavior of laminated steel sheets. They argued on buckling heights and global wrinkling patterns that were obtained in order to study the initiation condition of wrinkling and the post-buckling behavior of the sheets and to provide verification data for numerical predictions. Gresham et al. [16] studied on drawing behavior of metal composite sandwich structures. They observed that blank holder force has a significant effect on the failure mode of the metalcomposite system with lower forces resulting in wrinkling as the dominate mode and higher forces resulting in splitting and fracture. Padmanabhan et al. [17] concentrated on influence of process parameters on the deep drawing. They showed that die radius has the greatest influence on the deep drawing of stainless steel blank sheet followed by the blank holder force and the friction coefficient. Further, it is shown that a blank holder force application and local lubrication scheme improved the quality of the formed part. Lin et al. [18] investigated predictive modeling for optimization of textile composite forming. They carried out the effects of varying the normal force distribution across the edges of the blank and blank size. They showed that wrinkling can be minimized by optimizing the force distribution around the edge of the manufacturing tool and by careful choice of forming temperature. Narayanasamy and Loganathan [19] investigated the wrinkling limit diagrams of cold rolled and close annealed of different grades of IF Steel sheets. They studied on deep drawing into cylindrical cups through conical and tractrix dies. They showed that when a conical or a tractrix die is employed, the need for a hold down or clamping ring is eliminated. Demirci et al. [20] investigated the effect of the blank holder force on drawing of aluminum alloy square cup. They found out that the depth of the drawn cup increases in direct proportion with the force applied by the blank holder plate on the sheet. Jalali Aghchai et al. [21] studied formability of two-layer (Al1100St12) sheet. They

applied M-K model to the two-layer sheet and obtained the forming limit diagram theoretically. In this paper, wrinkling and fracture of circular single layer and two-layer sheets are investigated. In the numerical studies, minimum BHF to prevent initiation of wrinkling and required forming force are calculated via finite element simulation of the deep drawing process. Then, in order to verify these results, several experimental tests were performed on ST12 and Al1100 sheets and also on ST12Al1100 two-layer sheets with two different lay-ups. By comparing the results of FE and experimental investigations, effect of material and lay-up on appropriate BHF and forming forces has been studied.

2 Numerical modeling The effect of required BHF and forming force on the wrinkling and fracture of single layer and two-layer sheets is studied by finite element simulations on ABAQUS/CAE 6.7 Explicit/FEM code. The geometrical setup which was used in these simulations is illustrated in Fig. 1. Due to symmetry, only one quarter of the deformable blank and rigid tools are meshed. The blanks were meshed by using 3D stress, eight node, and C3D8R elements. Penalty contact interfaces were used to enforce the intermittent contact surfaces and sliding boundary condition between the sheet metal and the tooling elements. The friction coefficient between different contact surfaces has been shown in Table 1. The middle layer is bonded tightly with the internal and external layers, and its material model used in simulation is the power-law model with isotropic material model which

Fig. 1 One quarter model for FE analysis

Int J Adv Manuf Technol (2011) 54:113121 Table 1 Friction coefficient between contact surfaces [22, 23] Surfaces of contact Punch surface Blank holder surface Die surface Blank surface Blank surface Blank surface Friction coefficient 0.12 0.1 0.1

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keeps it free of wrinkling and fracture [23]. They showed that the friction coefficients between the layers affect the forming process very much. Therefore, the larger the coefficients are, the better the middle layer can be formed. The die was constrained fully and the blank holder and the punch could move only along the Zdirection, corresponding to the central axis of the punch. Materials were used in the power hardening law for each layer. Because the middle layer, polyurethane, was extremely thin, it was assumed that the alignment of the middle layer would not affect the forming process, and its material model used in simulation is the power-law model with isotropic material model. The effect of parameters such as lay-up and material properties was studied by FE simulations.

with a compression load cell and a linear potentiometer for measuring forming loads and punch displacement was also used. The geometrical parameters of the die are given in Table 2. The mechanical properties of ST12 and aluminum 1100 were derived from tensile test and listed into Table 3. Polyurethane adhesive with the presented properties that are shown in Table 3 was applied to join these two materials for preparing a two-layer sheet. The stressstrain relationship for this material which was derived from a tensile test is shown in Fig. 3. To perform the tests, blanks with the diameter of 77 mm is pushed into the die by the axial movement of the punch with the speed of 5 mm/s, and blank holder keeps the sheet flow steady during the process. In two-layer sheets, the layup in which ST12 sheet is on the top of Al1100 sheet is called S.I. lay-up and the other one that in which Al1100 sheet is on the top of ST12 is called A.I. lay-up.

4 Results and discussion 4.1 Blank holder force For each of ST12, Al1100, and ST12Al1100 (A.I. and S.I. lay-up) sheets, several deep drawing tests were carried out with different BHFs which are gradually increasing from the low value that causes wrinkle to a minimum value that eliminates wrinkling, while using BHFs higher than this value causes fracture during the deep drawing process. For Al1100 sheets, experimental tests and FE simulations were executed under three different BHFs as is shown in Fig. 4. In the tests with the BHF of 7.5 kN in experimental test and with the BHF of 7.21 kN in finite element simulation, wrinkling was occurred. By increasing

3 Experimental studies A die with constant blank holder force is designed in order to perform experimental tests. An annular blank holder exerts the BHF on the blank flange area. The thicknesses of ST12 and Al1100 sheets are both 1.2 mm, and the two-layer sheet is made of 0.7 mm ST12 and 0.5 mm Al1100 sheets. The experimental setup has been shown in Fig. 2. A 50-ton hydraulic press along

Fig. 2 Experimental setup and deformed parts

116 Table 2 Geometrical parameters of tool Die diameter (mm) Punch diameter (mm) Die edge radius (mm) Punch edge radius (mm) Clearance (mm) 40 35 5 5 2.5

Int J Adv Manuf Technol (2011) 54:113121

BHF to the value of 11.2 kN in experimental test and to the BHF of 10.82 kN in finite element simulation, a desirable part without any defect was produced, while using the BHF of 12.7 kN in experimental test and using the BHF of 12.36 kN in finite element simulations caused fracture in the drawn sheet due to preventing appropriate metal flow. As illustrated in Fig. 5, in both experimental and FE investigations on ST12 sheets, higher BHF of 20.2 kN in experimental test and higher BHF of 19.57 kN in finite element simulations were required to generate a proper part. Using BHFs of 15.2 and 22.4 kN resulted in wrinkling and fracture, respectively, in experimental tests and using BHFs of 14.87 and 21.9 kN caused wrinkling and fracture, respectively, in finite element simulations. With the intention of studying the effect of different BHFs on performance of two-layer sheets in deep drawing process, experimental and FE investigations were performed on two lay-ups of ST12Al1100 sheet (A.I. and S. I. lay-up). The minimum BHF for elimination of wrinkles in AI lay-up was 18.7 kN in experimental test and 18.35 kN in finite element simulations. A less value of 14 kN in experimental test and a less value of 13.57 kN in finite element simulations caused wrinkle, and higher value of 20.3 kN in experimental test and higher value of 20.04 kN in finite element simulations resulted in fracture in this layup as shown Fig. 6. For SI lay-up, in which stronger material is on the top, using BHF of 13.6 kN in experimental test and 13.23 kN in

Fig. 3 Experimental setup and deformed parts

finite element simulation was not able to avoid wrinkling; therefore, the BHF of 17.4 kN in experimental test and 17.07 kN in finite element simulation was used, and it was successful to produce a part free of any defect. Applying more BHFs like 19.2 kN in experimental test and 18.77 kN in finite element simulation also caused fracture in the sheet as shown Fig. 7. Based on the experimental and FE results for different mode that has been presented in Table 4, the minimum BHF for ST12 sheet, 20.2 kN in experimental test and 19.57 kN in finite element simulation, is larger than the value required for Al1100 sheet, 11.2 kN in experimental test and 10.82 kN in finite element simulation. Then, it can be concluded that the sheet with higher strength requires more BHF rather than the sheet with lower strength. Also, less BHF can be used for a sheet with higher ductility to control its wrinkling. The most interesting result is that the required BHF for both two-layer sheets are between the required BHFs for ST12 and Al1100 sheets. It means that the required BHF for a two-layer sheet depends on the characteristics of its

Table 3 Multilayer sheets properties

Properties Specific gravity (kg/m3) Poisson ratio, Young module (GPa) Yield stress (MPa) Strength coefficient (MPa), K Deformation hardening coefficient, n r0 r45 r90

Polyurethane 1,300 0.29 90 43

Al 1100 2,710 0.33 69.8 47.9 99 0.19 0.65 0.69 0.61

ST 12 7,800 0.3 200 205 452 0.32 1.32 1.54 1.15

Int J Adv Manuf Technol (2011) 54:113121 Fig. 4 Final blank shapes with different BHFs for Al1100, experimental and FEM results

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component and is less than the BHF for the stronger sheet and more than the BHF of weaker one. Furthermore, for two-layer sheets, it has been observed that the required BHF for A.I. lay-up is higher than the BHF for
Fig. 5 Final blank shapes with different BHFs for ST12, experimental and FEM results

S.I. lay-up. This can be related to the higher value of induced tension in flange area for this lay-up rather than the value for S.I. lay-up; consequently, the value of minimum required BHF is higher for A.I. lay-up.

118 Fig. 6 Final blank shapes with different BHFs for (Al1100 ST12) A.I. lay-up, experimental and FEM results

Int J Adv Manuf Technol (2011) 54:113121

Fig. 7 Final blank shapes with different BHFs for (ST12Al1100) S.I. lay-up, experimental and FEM results

Int J Adv Manuf Technol (2011) 54:113121 Table 4 Experimental and FEM results of BHF for studied cases

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4.2 Drawing ratio Usually deep-draw ability is related to the ratio of materials strength to the load necessary to draw-in the flange material. These values are substituted by the ratio of the
Fig. 8 The maximum punch load- drawing ratio curve for Al1100ST12 (A.I. and S.I. lay-ups)

punch load. When stretching, the stress state is biaxial tension. Moreover, the in-plane stress distribution along the thickness caused by bending must be considered as well. However, the maximum punch load is smaller in blank with lower strength. Therefore, the frictional stress is lower as

120 Table 5 Experimental and FEM results of forming force for studied cases Components

Int J Adv Manuf Technol (2011) 54:113121

ExpFEM Lay-up Maximum forming force (kN; experimental) Maximum forming force (kN; FEM) Deviation % Exp 100

ST 12-Al1100 A.I. S.I. ST12 Al1100

9.77 9.25 10.95 7.2

8.91 8.47 9.96 6.75

8.8 8.4 9.0 6.2

the material on the die is a blank with lower strength. It can be concluded that the sheet with higher strength requires more BHF rather than the sheet with lower strength. The results for (Al1100St12) are plotted in Fig. 8. It is shown that the required forming force increases when drawing ratio decrease. That is, the increase in initial blank diameter increases the required forming force. The results of experimental tests for different draw ratio are depicted in Fig. 8. It can also be concluded that by the rise of LDR and consequently the rise of maximum blank diameter, the area of surface contact among sheet, die, and blank holder surfaces increases. On the other hand, the rise in the punch load increases the surface forces. As a result, higher BHF values are required for such a condition. 4.3 Forming force The values of measured forming forces from experiments are given in Table 5. As previously mentioned, the resultant yield

stress of the two-layer sheet is a function of its components yield stress. This value is higher for ST12 sheet rather than Al1100. Consequently, the forming force of ST12 sheet is higher than the required forming force of Al1100 sheet as can be seen in Table 5, while the forming force for ST12 Al1100 (A.I. and S.I. lay-up) is less than the forming force for ST12 sheet and more than the one for Al1100 sheet since the mechanical properties of two-layer sheet depends on its components and is more than the weaker sheet and less than the stronger one. The decrease in forming force for the S.I. lay-up is in sequence of two parameters. First, the frictional stress between the die and the sheet is less for aluminum sheet in comparison to steel sheet that causes the decrease in forming forces. Second, the resultant bending and unbending load is less for S. I. lay-up due to increase of bending radius. Table 5 presents the final forming force in experimental and finite element investigations, and Fig. 9 shows forming force measured experimentally and numerically for all studied cases.

Fig. 9 Forming force- punch displacement curve for ST12, Al1100, ST12Al1100 (S.I. and A.I. lay-ups). a Experimental results, b FEM results

Int J Adv Manuf Technol (2011) 54:113121

121 6. Amziane-Hassani H, Neale KW (1991) On the analysis of sheet metal wrinkling. Int J Mech Sci 33:1430 7. Yang DY, Lee HS (1991) An analysis of hemispherical punch stretching by the energy method. Int J Mech Sci 33:435 8. Sukhomlinov LG, Engelsberg VK, Davgdov VN (1992) A finite element membrane model for the analysis of axisymmetric sheet metal forming processes. Int J Mech Sci 34:179 193 9. Kampus Z, Kuzman K (1992) Experimental and numerical (FEM) analysis of deep drawing of relatively thick sheet metal. J Mater Process Technol 34:133140 10. Wang CH, Kinzel G, Altan T (1994) Wrinkling criterion for an anisotropic shell with compound curvatures in sheet forming. Int J Mech Sci 36:945960 11. Mori T, Kurimoto S (1996) Press-formability of stainless steel and aluminum clad sheet. J Mater Process Technol 56:242253 12. Zeng XM, Mahdavian SM (1998) Critical conditions of wrinkling in deep drawing at elevated temperature. J Mater Process Technol 84:3846 13. Parsa MH, Yamaguchi K, Takahura N (2001) Redrawing analysis of aluminum-stainless steel laminate sheet using FEM simulations and experiments. Int J Mech Sci 43:23312347 14. Cao J, Wang X, Mills FA (2002) Characterization of sheet buckling phenomenon subjected to controlled boundary constraints. ASME J Manuf Sci Eng 124(8):493501 15. Cheng HS, Cao J, Yao H, Liu SD, Kinsey B (2004) Wrinkling behavior of laminated steel sheets. J Mater Process Technol 151:133140 16. Gresham J, Cantwell W, Cardew-Hall MJ, Compston P, Kalyanasundaram S (2006) Drawing behaviour of metal composite sandwich structures. Compos Struct 75:305312 17. Padmanabhan R, Baptista AJ, Oliveira MC, Menezes LF (2007) Effect of anisotropy on the deep-drawing of mild steel and dualphase steel tailor-welded blanks. J Mater Process Technol 184:288293 18. Lin H, Wang J, Long AC, Clifford MJ, Harrison P (2007) Predictive modeling for optimization of textile composite forming. Compos Sci Technol 67:32423252 19. Narayanasamy R, Loganathan C (2008) Study on wrinkling limit of interstitial free steel sheets of different thickness when drawn through conical and tractrix dies. Mater Des 29:14011411 20. Demirci HI, Esner C, Yasar M (2008) Effect of the blank holder force on drawing of aluminum alloy square cup: theoretical and experimental investigation. J Mater Process Technol 206:152160 21. Jalali Aghchai H, Shakeri M, Mollaei-Dariani B (2008) Theoretical and experimental formability study of two-layer metallic sheet (Al1100/St12). Proc IMechE Part B J Engineering Manufacture JEM 1140(222):11311138 22. Chen L, Yang JC, Zhang LW, Yuan SY (2007) Finite element simulation and model optimization of blank holder gap and shell element type in the stamping of a washing-trough. J Mater Process Technol 182:637643 23. Lang L, Danckert J, Nielsen KB (2005) Multi-layer sheet hydro forming: experimental and numerical investigation into the very thin layer in the middle. J Mater Process Technol 170:524535

5 Conclusion The FE simulations and experimental observations have been conducted to study the wrinkling phenomenon in both single layer and two-layer sheet deep drawing. In this study, proper BHFs were driven to eliminate the wrinkling and to avoid the fracture in the single and two-layer sheets. Finally, required forming force for the studied cases was investigated. The following results are obtained: 1. The higher the strength of sheet material, the more the required BHF to eliminate its wrinkling during the deep drawing process. Also, less BHF can be used for a sheet with higher ductility to control its wrinkling. For instance, required BHF for Al1100 is about 44% less than the BHF for ST12. 2. The forming force of the sheet with higher yield strength is more than the sheet with lower strength as an example forming force of ST12 is up to 35% more than the forming force for Al1100. 3. An increase in initial blank diameter causes the drawing ratio to reduce, and subsequently, it increases required forming force. 4. The required BHF and forming force for a two-layer sheet depend on the characteristics of its components and are less than the values for the stronger sheet and more than the values of the weaker one. 5. The required BHF and forming force for AI lay-up are 7% and 5% higher than the values for SI lay-up, respectively. 6. A great compatibility between finite element and experimental results was observed for BHF and forming forces.

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