Journal of Materials Processing Technology 111 (2001) 170174

Investigation into wrinkling behavior in the elliptical cup deep drawing process by nite element analysis using bifurcation theory
J.B. Kima, J.W. Yoonb, D.Y. Yanga,*, F. Barlatc
a

Department of Mechanical Engineering, Korea Advanced Institute of Science and Technology (KAIST), 373-1, Kusung-dong, Yusung-gu, Taejon 305-701, South Korea b LG Production Engineering Research Center, LG Electronic Inc., 19-1, Cheongho-Ri, Jinwuy-Myun, Pyungtaek-Si, Kyunggi-Do 451-713, South Korea c Alcoa Technical Center, 100 Technical Drive, Alcoa Center, PA 15069-0001, USA

Abstract The initiation and growth of wrinkles in sheet metal forming processes are inuenced by many factors such as the stress state, the mechanical properties of the sheet material, the geometry of the body, and the contact conditions. It is difcult to analyze wrinkling initiation and growth considering these factors, because the effects of the factors are very complex and the wrinkling behavior may show a wide variation for small deviation of the factors. In this study, bifurcation theory is introduced for the nite element analysis of wrinkling initiation and growth. All the above mentioned factors are conveniently considered by the nite element method. The wrinkling initiation is determined by checking the determinant of the stiffness matrix at each iteration and the wrinkling behavior is analyzed by successive iteration with the perturbed guess along the eigenvector. The nite element formulation is based on the incremental deformation theory and elasticplastic material modeling. The nite element analysis is carried out using continuum-based resultant shell elements. The initiation and growth of wrinkling in the elliptical cup deep drawing process are analyzed by the proposed algorithm. The effect of the aspect ratio of a punch on the wrinkling behavior in the elliptical cup deep drawing process is investigated. # 2001 Elsevier Science B.V. All rights reserved.
Keywords: Wrinkling; Bifurcation; Sheet metal forming process; Finite element method

1. Introduction Wrinkling that is induced by plastic instability is one of the major defects in sheet metal forming processes. The initiation and growth of wrinkles are inuenced by many factors such as the stress ratio, the mechanical properties and geometry of the workpiece, and the contact conditions. The analysis of the wrinkling initiation and growth, considering all the factors is difcult because the effects of the factors are very complex and the wrinkling behavior may show a wide scatter of data for a small deviation of factors, as is common in instability phenomena. Study on wrinkling, therefore, has been carried out case-by-case for a given process, and a generalized wrinkling criterion that can be used effectively for various processes has not been proposed. An analytical study [1] that employed the plastic bifurcation theory contained so much assumptions on the contact conditions, blankholder treatment, and other process parameters that
* Corresponding author. Tel.: 82-42-869-3214; fax: 82-42-869-3210. E-mail address: dyyang@mail.kaist.ac.kr (D.Y. Yang).

the results can hardly be used in process design. Wrinkling has also been studied by nite element analysis [2,3]. There are two types of wrinkling analysis using the nite element method: the bifurcation analysis of perfect structure [2] and the non-bifurcation analysis employing initial imperfection [3]. The non-bifurcation analysis employing initial imperfections sometimes gives more reasonable results because all real structures have inherent imperfections, such as material non-uniformity or geometric unevenness. In the analysis, however, the results are sensitive to the initial imperfections and the solution procedures are theoretically not rigorous. Kim et al. [4] introduced the continuation method proposed by Riks [5] into the nite element analysis of the modied Yoshida buckling test [6] of perfect elastic plastic sheet. They proposed the modied Yoshida buckling test as a useful wrinkling test and showed the effectiveness of the test by nite element analysis. By using the bifurcation algorithm of a perfect structure, the wrinkling behavior of sheet metal was investigated more rigorously. In this study, wrinkling initiation and growth are analyzed by nite element analysis incorporating the bifurcation

0924-0136/01/$ see front matter # 2001 Elsevier Science B.V. All rights reserved. PII: S 0 9 2 4 - 0 1 3 6 ( 0 1 ) 0 0 5 0 4 - 0

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theory (continuation method) which was proposed by Riks [5] and was applied to a typical sheet metal forming process by Kim et al. [4]. The wrinkling initiation and growth in the elliptical cup deep drawing process are analyzed by the bifurcation method. Through the nite element analysis of wrinkling growth in the elliptical cup deep drawing process, the effect of the aspect ratio of an elliptical punch on wrinkling behavior has been investigated. 2. Finite element formulation The nite element formulation is based on the incremental deformation theory and elasticplastic material modeling. The continuum-based resultant shell element is employed and the anisotropy of the sheet metal is considered. The CBR (continuum-based resultant) shell element is employed for a shell undergoing large deformation and large rotation. The thesis of Stanley [7] offers a comprehensive overview of the degenerated solid element approach and related methodologies which involve some types of reduction to a resultant formulation. Yoon et al. [8] expanded the elastic-nonlinear CBR shell theory, the works of Stanley, to cover the elastic plastic analysis of sheet metal forming processes considering planar anisotropic material modeling. In this study, the nite element formulation by Yoon is introduced into the nite element analysis of wrinkling initiation and growth of sheet metal. Linearized nite element equations of the CBR shell are derived from the CB shell in the explicit form. The linearized CBR shell equation is nally given as follows: Kmatl Du Kgeom Du Fext u Fint u (1)

Riks [5] proposed the continuation method by which the post-bifurcation analysis can be carried out along the secondary solution path and implemented into the buckling analysis of an elastic shell structure. In this study, the continuation method is introduced into the elasticplastic nite element method in order to analyze the wrinkling phenomenon in elliptical punch drawing. For a conservative system, the rst variation of the total potential energy vanishes for an equilibrium point and the second variation is positive denite for a stable system. In terms of the tangent stiffness, therefore, the condition for stability can be written as @2P dui duj Kij dui duj > 0 @ ui @ uj (3)

where P is the total potential energy and Kij the tangent stiffness. Therefore, the stability limit is reached at the point where the tangent stiffness Kij ceases to be positive denite, i.e., detK 0. The solution path past the bifurcation point should not be the primary path, but the secondary path. The trial increment of the nodal displacement along the secondary path is given as Dus aDup bv (4) where a and b are positive constants which should be determined, and v is the eigenvector at a singular point. The constant a is determined to minimize the total deformation energy, and the constant b is determined from the condition that the secondary path should be orthogonal to the primary path. The equilibrium solution along the secondary path is obtained by the NewtonRaphson iteration method with the initial guess calculated from Eq. (4). 4. Implementation of bifurcation algorithm on sheet metal forming processes The wrinkling initiation and growth in the elliptical cup deep drawing process are analyzed by the nite element method incorporating the bifurcation method. The analyses are carried out for various cases of different punch and die dimensions. The wrinkling behavior for various aspect ratios of elliptical cups are discussed. The material constants and sheet geometry used in the analysis are as follows: sheet material, A6111-T4; Poisson's ratio, 0.33; yield stress, 185.92 MPa; Young's modulus, 69 GPa; stressstrain curve,  454:76 268:84 exp6:45e MPa; anisotropic coefs cients for Hill's normal anisotropy,  r 0:994; friction coefcient, 0.1; sheet thickness, 0.9144 mm; and blankholding force, 4 kN. For the analysis of wrinkling initiation and growth, a twoface-contact treatment algorithm of a shell element and the blankholding force control technique are employed. At the initial stage of deep drawing, all the nodes of the ange part are in contact with the die and blankholder. As the process proceeds, however, the nodes between the die shoulder and

where Kmatl, Kgeom and Fint are the material stiffness matrix, the geometric stiffness matrix, and the internal force vector, respectively, and are given as follows: Z Z Kmatl Du deT D1 De ds; Fint u deT S1 ds; s s Z (2) Kgeom Du dgT i S2 Dgi ds
s

In the equation, De, D1, S1, S2, gi are the strain resultant vector, the constitutive resultant matrix, the stress resultant vector, the stress resultant matrix, and the displacement gradient resultant vector, respectively. 3. Bifurcation algorithm In the bifurcation problem, the stiffness matrix of linearized nite element equation becomes singular at a bifurcation point and the solution procedure by the Newton Raphson method cannot be advanced. The buckling of a column, the buckling of a compressed circular plate and the wrinkling of a deep drawn cup are all bifurcation problems.

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Table 1 Dimensions of the punch and die for the analysis of the elliptical cup deep drawing process for various tool dimensions Analysis Punch (mm) Major axis (2ap) I II III IV V 80 80 80 80 80 Minor axis (2bp) 40 50 60 70 80 Shoulder radius (rp) 6 6 6 6 6 Die (mm) Major axis (2ad) 86 86 86 86 86 Minor axis (2bd) 46 56 66 76 86 Shoulder radius (rd) 7 7 7 7 7

the sheet edge do not come into contact with the die or blankholder because the gap between the die and holder increases by reaction force or the thickening of the sheet at the edge. In order to consider the thickening of the sheet in contact treatment, a two-face-contact treatment is employed. At the rst stage of wrinkling initiation, bifurcation takes place with the maximum amplitude of the gap between the die and blankholder. After the bifurcation, wrinkling grows while keeping the equilibrium with the blankholding force. The solution route of a non-linear equation is carried out rst, and then the route of blankholding force equilibrium is carried out. The analyses are carried out for ve cases of punch shape. The dimensions of punch and die are given in Table 1. A circular sheet of 140 mm diameter is used for the initial blank. In the analysis, after having imposed the symmetric boundary condition, only a quarter of the circular blank is discretized into 750 elements and 806 nodes as shown in Fig. 1. Fig. 2 shows the wrinkling initiation and growth for the case of Analysis IV. When the punch stroke reaches 13 mm, the bifurcation takes place. The eigenmode shown in Fig. 2(c) is magnied three times. As the punch proceeds further, the wrinkles also grow more (Fig. 2(d)(e)). In Fig. 2(c)(e), it is shown that wrinkling is severe in the region near to the major axis. Fig. 3 shows the deformed shapes when the punch stroke reaches 20 mm. For the case of Analysis IV, wrinkling takes place. For the cases of Analyzes IIII and V, however,

wrinkling does not take place. Fracture takes place at the punch shoulder of the major axis for the case of Analysis I. Fig. 4 shows the deformed shapes when the punch stroke reaches 30 mm. In the case of Analysis III, wrinkling takes place as shown in Fig. 4(b) in addition to the case of Analysis IV. It is shown that the wavelength of the wrinkles is shorter in the region near to the major axis than in the region near to

Fig. 1. Initial nite element system (750 elements and 806 nodes).

Fig. 2. Initiation and growth of wrinkling in elliptical cup deep drawing: (a) initial; (b) stroke: 13 mm; (c) stroke: 13 mm, eigenmode (3); (d) stroke: 20 mm; (e) stroke: 30 mm.

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Fig. 3. Deformed shapes for various aspect ratios of elliptical punch at the punch stroke of 20 mm. Analysis: (a) I a=b 2:0; (b) II a=b 1:6; (c) III a=b 1:33; (d) IV a=b 1:14; (e) V a=b 1:0.

the minor axis. For the case of Analysis II, fracture takes place on the punch shoulder in addition to the case of Analysis I. For the case of Analysis V (cylindrical cup deep drawing), wrinkling or fracture does not take place.

Fig. 5 shows the gap between the blankholder and die. Because the thickness of the sheet is 0.9144 mm, the initial gap is also 0.9144 mm. It is shown that wrinkling takes place rst in the case of Analysis IV and secondly in the case of

Fig. 4. Deformed shapes for various aspect ratios of an elliptical punch at a punch stroke of 30 mm. Analysis: (a) II a=b 1:6; (b) III a=b 1:33; (c) IV a=b 1:14; (d) V a=b 1:0.

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5. Conclusions The bifurcation algorithm is introduced in the elastic plastic nite element method in order to analyze the wrinkling initiation and growth in the elliptical cup deep drawing process. A two-face-contact treatment scheme and blankholder control algorithm are employed. The wrinkling initiation and growth in the elliptical cup deep drawing process are analyzed by the proposed nite element method. It is shown that wrinkling is severe on the region near to the major axis. Through the forming analyses of elliptical cups having various aspect ratios, the tendency of wrinkling and fracture has been investigated. For the case of the aspect ratio of 1.33, wrinkling takes place rst. As the aspect ratio of the punch increases, wrinkling initiation is retarded and fracture takes place earlier near to the major axis.
Fig. 5. Blankholder gappunch displacement curve for various aspect ratios of the punch.

References
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Analysis III. For the other cases of analysis, wrinkling does not take place. From these results, it is shown that wrinkling takes place rst in the case of 80 mm of the major axis and 60 mm of the minor axis of the punch (aspect ratio of 1.33). As the aspect ratio (the ratio of the major axis to the minor axis) of punch increases, wrinkling initiation is retarded and fracture takes place earlier near to the major axis.