Analysis of ESAFORM 2021 cup drawing benchmark of an Al alloy, critical factors for accuracy and efficiency of FE simulations

• Published in: International journal of material forming Vol. 15; no. 5; p. 61
• Main Authors: Habraken, Anne Marie, Aksen, Toros Arda, Alves, José L., Amaral, Rui L., Betaieb, Ehssen, Chandola, Nitin, Corallo, Luca, Cruz, Daniel J., Duchêne, Laurent, Engel, Bernd, Esener, Emre, Firat, Mehmet, Frohn-Sörensen, Peter, Galán-López, Jesús, Ghiabakloo, Hadi, Kestens, Leo A. I., Lian, Junhe, Lingam, Rakesh, Liu, Wencheng, Ma, Jun, Menezes, Luís F., Nguyen-Minh, Tuan, Miranda, Sara S., Neto, Diogo M., Pereira, André F. G., Prates, Pedro A., Reuter, Jonas, Revil-Baudard, Benoit, Rojas-Ulloa, Carlos, Sener, Bora, Shen, Fuhui, Van Bael, Albert, Verleysen, Patricia, Barlat, Frederic, Cazacu, Oana, Kuwabara, Toshihiko, Lopes, Augusto, Oliveira, Marta C., Santos, Abel D., Vincze, Gabriela
• Format: Journal Article Web Resource
• Language: English
• Published: Paris Springer Paris 01.09.2022; Springer Nature B.V; Springer-Verlag Italia s.r.l
• Subjects: 6016-T4 aluminium alloy; 6016-t4 aluminum alloy; Accuracy; Aluminum base alloys; Benchmark; Benchmarks; CAE) and Design; Computational Intelligence; Computer-Aided Engineering (CAD; Constitutive law; Contact; Control; Cube texture; Datasets; Deep drawing; Deep drawing modeling; Deep drawing modelling; Dynamical Systems; Earing; Earing profile prediction; Engineering; Engineering, computing & technology; ESAFORM 25 Years On; Finite elements simulation; Force prediction; Force predictions; General Materials Science; Ingénierie, informatique & technologie; Machines; Manufacturing; Materials Science; Materials science & engineering; Materials Science (all); Mechanical Engineering; Model comparisons; Models comparisons; Plastic properties; Processes; Profile prediction; Redundancy; Science des matériaux & ingénierie; Shear tests; Simulation; Tensile tests; Thickness prediction; Vibration; Yield stress; Thickness prediction; Benchmark; Model comparisons; Deep drawing modelling; 6016-T4 aluminium alloy; Force prediction; Earing profile prediction
• ISSN: 1960-6206; 1960-6214; 1960-6214
• DOI: 10.1007/s12289-022-01672-w

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.