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1 Journal of Achievements in Materials and Manufacturing Engineering

1 2007

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Numerical determination of the forming limit diagrams

Pepelnjak T., Kuzman K.

Journal of Achievements in Materials and Manufacturing Engineering

2007

Vol. 20, nr 1-2

375-378

Purpose: At present the industrial practice demands a reliable determination of forming limits which assures the prediction of properly selecting the forming process in a digital environment. Therefore, technological limits defined with the forming limit diagrams (FLDs) have to be known. The experimental evaluation of FLDs for sheet metal is time consuming and demands expensive equipment. The experimental work could be omitted by predicting the FLD with numerical simulations. Design/methodology/approach: The paper presents a methodology to determine the entire range of the FLD for sheet metal in a digital environment. The Marciniak testing procedure simulated with the FEM program ABAQUS was selected to determine the FLD. To assure the reliability of the developed method, different materials were analysed: two types of deep drawing steel, an aluminium 3000 alloy, and a Ti-alloy. The selected materials have different mechanical properties and sheet thicknesses ranging from 0.5 mm to 1.23 mm. For the verification of numerically obtained results parallel experimental determinations of the FLDs were performed showing a good correlation between the FLDs obtained by both approaches. Findings: A specially developed method for the evaluation of the thickness strain as a function of time as well as the first and the second time derivation of the thickness strain enable the determination of the onset of necking. Research limitations/implications: The presented method of the digital evaluation of the FLDs is still in a developmental phase and needs further improvements for industrial practice. However, in some cases the numerical approach had already been used for a fast prediction of the FLD prior to performing the experiments. At the current level the developed program still needs an expert to support it in some critical decisions. Originality/value: Considering some methological improvements and automation procedures the developed method could be used in everyday practice.