6016-T4 aluminium alloy; Benchmark; Deep drawing modelling; Earing profile prediction; Force prediction; Model comparisons; Thickness prediction; 6016-t4 aluminum alloy; Constitutive law; Deep drawing modeling; Finite elements simulation; Force predictions; Models comparisons; Profile prediction; Materials Science (all); General Materials Science
Abstract :
[en] This article details the ESAFORM Benchmark 2021. The deep drawing cup of a 1 mm thick, AA 6016-T4 sheet with a strong cube texture was simulated by 11 teams relying on phenomenological or crystal plasticity approaches, using commercial or self-developed Finite Element (FE) codes, with solid, continuum or classical shell elements and different contact models. The material characterization (tensile tests, biaxial tensile tests, monotonic and reverse shear tests, EBSD measurements) and the cup forming steps were performed with care (redundancy of measurements). The Benchmark organizers identified some constitutive laws but each team could perform its own identification. The methodology to reach material data is systematically described as well as the final data set. The ability of the constitutive law and of the FE model to predict Lankford and yield stress in different directions is verified. Then, the simulation results such as the earing (number and average height and amplitude), the punch force evolution and thickness in the cup wall are evaluated and analysed. The CPU time, the manpower for each step as well as the required tests versus the final prediction accuracy of more than 20 FE simulations are commented. The article aims to guide students and engineers in their choice of a constitutive law (yield locus, hardening law or plasticity approach) and data set used in the identification, without neglecting the other FE features, such as software, explicit or implicit strategy, element type and contact model.
Disciplines :
Materials science & engineering
Author, co-author :
Habraken, Anne ; Université de Liège - ULiège > Département ArGEnCo > Département Argenco : Secteur MS2F
Aksen, Toros Arda; Mechanical Engineering Department, University of Sakarya, Esentepe Campus, M7, 54050 Serdivan, Sakarya Turkey
Alves, José L; CMEMS, Microelectromechanical Systems Research Unit, University of Minho, Campus de Azurém, 4800-058 Guimarães, Portugal
Amaral, Rui L; Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), R. Dr. Roberto Frias 400, 4200-465 Porto, Portugal
Betaieb, Ehssen ; Université de Liège - ULiège > Urban and Environmental Engineering
Chandola, Nitin; Department of Mechanical and Aerospace Engineering, University of Florida, REEF, 1350N. Poquito Rd, Shalimar, FL 32579 USA
Corallo, Luca; Department of Electromechanical, Systems and Metal Engineering, MST-DyMaLab Research Group, Ghent University, Technologiepark 46, 9052 Zwijnaarde, Belgium
Cruz, Daniel J; Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), R. Dr. Roberto Frias 400, 4200-465 Porto, Portugal
Duchene, Laurent ; Université de Liège - ULiège > Département ArGEnCo > Analyse multi-échelles dans le domaine des matériaux et structures du génie civil
Engel, Bernd; Forming Technology (UTS), Institute of Production Technologies, University of Siegen, Breite Strasse, 11, 57076 Siegen, Germany
Firat, Mehmet; Mechanical Engineering Department, University of Sakarya, Esentepe Campus, M7, 54050 Serdivan, Sakarya Turkey
Frohn-Sörensen, Peter; Forming Technology (UTS), Institute of Production Technologies, University of Siegen, Breite Strasse, 11, 57076 Siegen, Germany
Galán-López, Jesús; MSE, Faculty 3mE, Delft University of Technology, Mekelweg 2, 2628 CD Delft, The Netherlands
Ghiabakloo, Hadi; Department of Materials Engineering, KU Leuven, Leuven, Belgium
Kestens, Leo A I; Department of Electromechanical, Systems and Metal Engineering, Ghent University, Ghent, Belgium
Lian, Junhe; Advanced Manufacturing and Materials, Department of Mechanical Engineering, Aalto University, Puumiehenkuja 3, 02150 Espoo, Finland
Lingam, Rakesh; Graduate Institute of Ferrous and Energy Materials Technology, Pohang University of Science and Technology, 77 Cheongam-ro, Nam-gu, Pohang, Gyeongbuk 37673 Republic of Korea ; Indian Institute of Technology Dharwad, P.B. Road, Dharwad, Karnataka 580011 India
Liu, Wencheng; School of Civil Aviation, Northwestern Polytechnical University, Taicang, 215400 China
Ma, Jun; Department of Mechanical and Industrial Engineering, Norwegian University of Science and Technology, 7491 Trondheim, Norway
Menezes, Luís F; CEMMPRE, Department of Mechanical Engineering, University of Coimbra, Polo II, Pinhal de Marrocos, 3030-788 Coimbra, Portugal
Nguyen-Minh, Tuan; Department of Electromechanical, Systems and Metal Engineering, Ghent University, Ghent, Belgium
Miranda, Sara S; Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), R. Dr. Roberto Frias 400, 4200-465 Porto, Portugal
Neto, Diogo M; CEMMPRE, Department of Mechanical Engineering, University of Coimbra, Polo II, Pinhal de Marrocos, 3030-788 Coimbra, Portugal
Pereira, André F G; CEMMPRE, Department of Mechanical Engineering, University of Coimbra, Polo II, Pinhal de Marrocos, 3030-788 Coimbra, Portugal
Prates, Pedro A; CEMMPRE, Department of Mechanical Engineering, University of Coimbra, Polo II, Pinhal de Marrocos, 3030-788 Coimbra, Portugal ; Center for Mechanical Technology and Automation (TEMA), Department of Mechanical Engineering, University of Aveiro, Aveiro, Portugal
Reuter, Jonas; Forming Technology (UTS), Institute of Production Technologies, University of Siegen, Breite Strasse, 11, 57076 Siegen, Germany
Revil-Baudard, Benoit; Department of Mechanical and Aerospace Engineering, University of Florida, REEF, 1350N. Poquito Rd, Shalimar, FL 32579 USA
Rojas Ulloa, Carlos ; Université de Liège - ULiège > Département ArGEnCo > Département Argenco : Secteur MS2F
Shen, Fuhui; Advanced Manufacturing and Materials, Department of Mechanical Engineering, Aalto University, Puumiehenkuja 3, 02150 Espoo, Finland ; Steel Insititute, RWTH Aachen University, Intzestr. 1, 52072, Aachen, Germany
Van Bael, Albert; Department of Materials Engineering, KU Leuven, Leuven, Belgium
Verleysen, Patricia; Department of Electromechanical, Systems and Metal Engineering, MST-DyMaLab Research Group, Ghent University, Technologiepark 46, 9052 Zwijnaarde, Belgium
Barlat, Frederic; Graduate Institute of Ferrous and Energy Materials Technology, Pohang University of Science and Technology, 77 Cheongam-ro, Nam-gu, Pohang, Gyeongbuk 37673 Republic of Korea
Cazacu, Oana; Department of Mechanical and Aerospace Engineering, University of Florida, REEF, 1350N. Poquito Rd, Shalimar, FL 32579 USA
Kuwabara, Toshihiko; Division of Advanced Mechanical Systems Engineering, Institute of Engineering, Tokyo University of Agriculture and Technology, 2-24-16 Nakacho, Koganei-shi, Tokyo, 184-8588 Japan
Lopes, Augusto; Department of Materials and Ceramic Engineering, CICECO, Universidade de Aveiro, 3810-193 Aveiro, Portugal
Oliveira, Marta C; CEMMPRE, Department of Mechanical Engineering, University of Coimbra, Polo II, Pinhal de Marrocos, 3030-788 Coimbra, Portugal
Santos, Abel D; Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), R. Dr. Roberto Frias 400, 4200-465 Porto, Portugal ; Faculty of Engineering, University of Porto, R. Dr. Roberto Frias 400, 4200-465 Porto, Portugal
Vincze, Gabriela; Center for Mechanical Technology and Automation (TEMA), Department of Mechanical Engineering, University of Aveiro, Aveiro, Portugal
The Benchmark organizers thank ESAFORM for the 10 000€ Benchmark Grant as well as the opportunity to perform and diffuse such a state-of-the-art about deep drawing simulations. As director of the Fund for Scientific Research (F.R.S.–FNRS) Anne Marie Habraken thanks this institution of Wallonia-Brussels Federation for its support. UA and UCoimbra acknowledge the support of the projects POCI-01-0145-FEDER-032362 (PTDC/EME-ESP/32362/2017), POCI-01-0145-FEDER-030592 (PTDC/EME‐EME/30592/2017), UIDB/00285/2020 and PTDC/EME‐EME/31216/2017 (POCI‐01‐0145‐FEDER‐031216). André Pereira (UC) was funded under this later project. All projects were financed by the Operational Program for Competitiveness and Internationalization, in its FEDER/FNR component, and the Portuguese Foundation of Science and Technology (FCT), in its State Budget component (OE). Sara S. Miranda is grateful to FCT for the Doctoral grant SFRH/BD/146083/2019. Carlos Rojas-Ulloa now PhD student of ULiege thanks Dommaco project for his mobility grant of the cooperation agreement WBI/AGCID SUB2019/419031 (DIE19-0005). Albert Van Bael acknowledges financial support from the FWO (K801421N). All the organizers did a marvellous job but, as responsible of this article, Anne Marie Habraken specifically thanks Marta C. Oliveira who organized so well the data collection, the results analysis and the interactions with all the participants, who are acknowledge for their positive reactions to our numerus requests. Special thanks to Oana Cazacu for her valuable input.The Benchmark organizers thank ESAFORM for the 10 000€ Benchmark Grant as well as the opportunity to perform and diffuse such a state-of-the-art about deep drawing simulations. As director of the Fund for Scientific Research (F.R.S.–FNRS) Anne Marie Habraken thanks this institution of Wallonia-Brussels Federation for its support. UA and UCoimbra acknowledge the support of the projects POCI-01-0145-FEDER-032362 (PTDC/EME-ESP/32362/2017), POCI-01-0145-FEDER-030592 (PTDC/EME‐EME/30592/2017), UIDB/00285/2020 and PTDC/EME‐EME/31216/2017 (POCI‐01‐0145‐FEDER‐031216). André Pereira (UC) was funded under this later project. All projects were financed by the Operational Program for Competitiveness and Internationalization, in its FEDER/FNR component, and the Portuguese Foundation of Science and Technology (FCT), in its State Budget component (OE). Sara S. Miranda is grateful to FCT for the Doctoral grant SFRH/BD/146083/2019. Carlos Rojas-Ulloa now PhD student of ULiege thanks Dommaco project for his mobility grant of the cooperation agreement WBI/AGCID SUB2019/419031 (DIE19-0005). Albert Van Bael acknowledges financial support from the FWO (K801421N).
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