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Material parameter identification for the

numerical simulation of deep-drawing of
aluminium alloys
B.M. Chaparro, J.M. Antunes, A.J. Baptista, D.M. Rodrigues, , J.V. Fernandes, L.F. Menezes

M2D'2006 - PORTO, 24-26 JULY

University of Coimbra

CENTRO DE ENGENHARIA MECNICA DA UNIVERSIDADE DE COIMBRA

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I.

Introduction

II.

Constitutive models

III. Inverse Analysis

IV. Demeri Test
V.

Conclusions

OUTLOOK
2

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Multiplicity of constitutive models

F ( ' X, L, k ) = ( ' X, M, k1 ) Y ( k 2 ) = 0

Equivalent stress
associated with the
yield criteria

Equivalent stress
associated with the work
hardening law

In this study, an automatic procedure for the identification of material

parameters according to several phenomenological elastoplastic
constitutive models was developed.

Introduction
3

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Hill, 1948 (Hill48)

F yy zz

+ G ( zz xx ) + H xx yy
2

+ 2 L yz + 2 M zx + 2 N xy = K 2
2

Barlat, 1991 (YLD91)

S1 S2

s = L:

+ S1 S3

+ S 2 S3

Plastic surface

= 2K m

(Isotropic Equivalent Stress)

( c2 + c3 ) / 3

c3 / 3
c2 / 3
L=
0

c3 / 3

c2 / 3
c1 / 3

c1 / 3

( c1 + c2 ) / 3

0
0
0

0
0

0
0

c4
0

0
c5

( c3 + c1 ) / 3

0
0

Constitutive Models - Yield Criteria

4

0
0

0
0

c6

m=6 for BCC materials

m=8 for FCC materials

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Isotropic hardening - Voce Law

= Y0 + Rsat (1 e n )
p

Y0 - Initial yield stress

Rsat - saturation stress

isotropic hardening

n - constant

Kinematic hardening - Lemaitre & Chaboche model

( X ) X & p

X& = C x X sat

Cx and Xsat are material parameters

kinematic hardening

Constitutive Models Work hardening law

5

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The calculation methodology is based on the best fit between each model
and the full set of available experimental results.
2

erroryield _ criteria

= w1 exp 1 + w2 exp 1

is the yield stress in tension for a specific orientation () with the rolling direction (RD)
exp

exp

is the r-ratio obtained in tension performed at a specific angle with the RD

and r denotes the corresponding values obtained from the yield criteria
wi are weighting factors

errorwork hardening

exp

= exp 1

is the experimental equivalent stress

denotes the corresponding values obtained from the hardening law.

Inverse Analysis
6

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Materials:
 EN AW-5182-H111

 EN AW-6120-T4

Inverse analysis - Results

7

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Experimental curves obtained in the tensile, shear and Baushingers shear

tests for the EN AW-5182-H111 aluminium alloy
400

Stress [MPa] 11 / 11

300
200
100
0
-0.4

-0.2

0.2

-100
-200
-300
Strain 11 / 12

Results - EN AW-5182 H111

8

0.4

0.6

0.8

5182_T_00
5182_T_15
5182_T_30
5182_T_45
5182_T_60
5182_T_75
5182_T_90
5182_S_00
5182_S_15
5182_S_30
5182_S_45
5182_S_60
5182_S_75
5182_S_90
5182_B_10
5182_B_20
5182_B_30

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Experimental yield stresses and r values for the EN AW-5182-H111 aluminium alloy
Angle with RD []
0
15
30
45
60
75
90

Yield stress [Mpa]

108.0
107.8
108.3
104.0
108.4
109.6
111.9

r values
0.707
0.688
0.741
0.859
0.707
0.799
0.807
2

erroryield _ criteria = w1 exp 1 + w2 exp 1

Hill48

F
0.5301
c1
1.0184

YLD91

G
0.5888
c2
1.0556

N
1.4252
c3
0.9484

c6
0.9860

m
8

Material parameters identified for the Hill48 and YLD91 yield criteria

Results - EN AW-5182 H111

9

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Comparison between experimental and numerical results

Yield stresses
1.4

0.8

0.8

0.6

0.6

0.4

0.4

0.2

0.2

-0.2
-0.2

0.2

0.4

0.6
Sx

0.8

Txy=0.000
Txy=0.250
Txy=0.433
Txy=0.500
EXP

1.2

Sy

Sy

1.4

Txy=0.000
Txy=0.250
Txy=0.433
Txy=0.500
EXP

1.2

-0.2
-0.2

1.2

 Hill48

0.2

0.4

0.6
Sx

0.8

YLD91

Results - EN AW-5182 H111

10

1.2

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Comparison between experimental and numerical results

r-values
1.0
0.9

0.8
EXP
HILL48
YLD91

0.7
0.6
0.5
0.4
0

15

30

45

60

75

90

Angle with RD

Results - EN AW-5182 H111

11

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Isotropic work hardening parameters identified using the

von Mises, Hill48 and YLD91 yield models

errorwork hardening = exp 1

Yield model
Von Mises
Hill48
YLD91

Results - EN AW-5182 H111

12

Rsat [MPa]

nv

221.1
212.0
232.9

11.4
11.52
10.91

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Experimental and numerical equivalent stress-strain curves considering

the von Mises yield criterion and pure isotropic work hardening
400
5182_T_00
5182_T_15
5182_T_30
5182_T_45
5182_T_60
5182_T_75
5182_T_90
5182_S_00
5182_S_15
5182_S_30
5182_S_45
5182_S_60
5182_S_75
5182_S_90
DD3MAT Voce Iso

Equiv. Stress [MPa]

350
300
250
200
150
100
50
0
0

0.1

0.2

0.3

0.4

0.5

Equiv. Strain

Results - EN AW-5182 H111

13

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Experimental and numerical equivalent stress-strain curves considering

the Hill 48 yield criterion and pure isotropic work hardening
400

Equiv. Stress [MPa]

350
300
250
200
150
100
50
0
0

0.1

0.2

0.3

Equiv. Strain

Results - EN AW-5182 H111

14

0.4

0.5

5182_T_00
5182_T_15
5182_T_30
5182_T_45
5182_T_60
5182_T_75
5182_T_90
5182_S_00
5182_S_15
5182_S_30
5182_S_45
5182_S_60
5182_S_75
5182_S_90
DD3MAT Voce Iso

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Experimental and numerical equivalent stress-strain curves considering

the YLD91 yield criterion and pure isotropic work hardening
400

Equiv. Stress [MPa]

350
300
250
200
150
100
50
0
0

0.1

0.2

0.3

0.4

0.5

5182_T_00
5182_T_15
5182_T_30
5182_T_45
5182_T_60
5182_T_75
5182_T_90
5182_S_00
5182_S_15
5182_S_30
5182_S_45
5182_S_60
5182_S_75
5182_S_90
DD3MAT Voce Iso

Equiv. Strain

Results - EN AW-5182 H111

15

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Isotropic and Kinematic work hardening parameters identified using the

von Mises, Hill48 and YLD91 yield models

errorwork hardening = exp 1

Yield model

Rsat [MPa]

nv

Cx

X sat [MPa]

Mises
Hill48
YLD91

174.9
162.9
196.8

10.3
11.0
9.1

32.3
25.0
53.0

43.8
44.7
40.0

Results - EN AW-5182 H111

16

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Experimental and numerical equivalent stress-strain curves considering the

von Mises yield criterion and isotropic and kinematic work hardening
400
Equiv. Stress [MPa]

300
200
100
0
-0.2

-0.1

-100 0

0.1

0.2

0.3

0.4

-200
-300
-400
Equiv. Strain
5182_T_00
5182_T_75
5182_S_45
5182_B_20

5182_T_15
5182_T_90
5182_S_60
5182_B_30

5182_T_30
5182_S_00
5182_S_75
DD3MAT_B_10

5182_T_45
5182_S_15
5182_S_90
DD3MAT_B_20

5182_T_60
5182_S_30
5182_B_10
DD3MAT_B_30

Results - EN AW-5182 H111

17

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Experimental and numerical equivalent stress-strain curves considering the

Hill 48 yield criterion and isotropic and kinematic work hardening
400
Equiv. Stress [MPa]

300
200
100
0
-0.2

-0.1

-100 0

0.1

0.2

0.3

0.4

-200
-300
-400
Equiv. Strain
5182_T_00
5182_T_75
5182_S_45
5182_B_20

5182_T_15
5182_T_90
5182_S_60
5182_B_30

5182_T_30
5182_S_00
5182_S_75
DD3MAT_B_10

Results - EN AW-5182 H111

18

5182_T_45
5182_S_15
5182_S_90
DD3MAT_B_20

5182_T_60
5182_S_30
5182_B_10
DD3MAT_B_30

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Experimental and numerical equivalent stress-strain curves considering the

YLD91 yield criterion and isotropic and kinematic work hardening
400
Equiv. Stress [MPa]

300
200
100
0
-0.2

-0.1

-100 0

0.1

0.2

0.3

0.4

-200
-300
-400
Equiv. Strain
5182_T_00
5182_T_75
5182_S_45
5182_B_20

5182_T_15
5182_T_90
5182_S_60
5182_B_30

5182_T_30
5182_S_00
5182_S_75
DD3MAT_B_10

5182_T_45
5182_S_15
5182_S_90
DD3MAT_B_20

5182_T_60
5182_S_30
5182_B_10
DD3MAT_B_30

Results - EN AW-5182 H111

19

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Experimental curves obtained in the tensile, shear and Baushingers shear

tests for the EN AW-6120-T4 aluminium alloy

Results - EN AW- 6120 T4

20

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Experimental yield stresses and r values for the EN AW-6120 T4 aluminium alloy
Angle with RD []
0
15
30
45
60
75
90

r value
0.691
0.690
0.557
0.476
0.530
0.654
0.692

Yield stress [MPa]

104.5
106.4
106.1
104.1
105.6
103.1
98.3
2

erroryield _ criteria = w1 exp 1 + w2 exp 1

Hill48

F
0.618
c1
1.079

YLD91

G
0.580
c2
1.066

N
1.186
c3
0.970

c6
0.941

m
8

Material parameters identified for the Hill48 and YLD91 yield criteria

Results - EN AW-6120 T4
21

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Comparison between experimental and numerical results

Yield stresses
1.4

1.2

0.8

0.8

0.6

0.6

0.4

0.4

0.2

0.2

-0.2
-0.2

-0.2
-0.2

0.2

0.4

0.6
Sx

0.8

Txy=0.000
Txy=0.250
Txy=0.433
Txy=0.500
EXP

1.2

Sy

Sy

1.4

Txy=0.000
Txy=0.250
Txy=0.433
Txy=0.500
EXP

1.2

 Hill48

0.2

0.4

0.6
Sx

0.8

YLD91

Results - EN AW-6120 T4
22

1.2

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Comparison between experimental and numerical results

r-values
1.0
0.9

0.8
EXP
HILL48
YLD91

0.7
0.6
0.5
0.4
0

15

30

45

60

75

90

Angle with RD

Results - EN AW-6120 T4
23

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Isotropic work hardening parameters identified using the

von Mises, Hill48 and YLD91 yield models

errorwork hardening = exp 1

Yield model

Rsat [MPa]

nv

Mises
Hill48
YLD91

164.0
156.4
170.4

13.3
11.9
12.9

Results - EN AW-6120 T4
24

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Experimental and numerical equivalent stress-strain curves considering

the von Mises yield criterion and pure isotropic work hardening
300

Equiv. Stress [MPa]

250
200
150
100
50
0
0

0.1

0.2

0.3

0.4

0.5

6120_T_00
6120_T_15
6120_T_30
6120_T_45
6120_T_60
6120_T_75
6120_T_90
6120_S_00
6120_S_15
6120_S_30
6120_S_45
6120_S_60
6120_S_75
6120_S_90
DD3MAT Voce Iso

Equiv. Strain

Results - EN AW-6120 T4
25

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Experimental and numerical equivalent stress-strain curves considering

the Hill 48 yield criterion and pure isotropic work hardening
300

Equiv. Stress [MPa]

250
200
150
100
50
0
0

0.1

0.2

0.3

Equiv. Strain

Results - EN AW-6120 T4
26

0.4

0.5

6120_T_00
6120_T_15
6120_T_30
6120_T_45
6120_T_60
6120_T_75
6120_T_90
6120_S_00
6120_S_15
6120_S_30
6120_S_45
6120_S_60
6120_S_75
6120_S_90
DD3MAT Voce Iso

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Experimental and numerical equivalent stress-strain curves considering

the YLD91 yield criterion and pure isotropic work hardening
300

Equiv. Stress [MPa]

250
200
150
100
50
0
0

0.1

0.2

0.3

0.4

0.5

6120_T_00
6120_T_15
6120_T_30
6120_T_45
6120_T_60
6120_T_75
6120_T_90
6120_S_00
6120_S_15
6120_S_30
6120_S_45
6120_S_60
6120_S_75
6120_S_90
DD3MAT Voce Iso

Equiv. Strain

Results - EN AW-6120 T4
27

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Isotropic and Kinematic work hardening parameters identified using the

von Mises, Hill48 and YLD91 yield models

errorwork hardening = exp 1

Yield model

Rsat [MPa]

nv

Cx

X sat [MPa]

von Mises
Hill48
YLD91

138.2
114.8
142.9

9.8
9.2
9.4

68.2
31.7
69.4

35.5
43.7
37.2

Results - EN AW-6120 T4
28

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Experimental and numerical equivalent stress-strain curves considering the

von Mises yield criterion and isotropic and kinematic work hardening

Equiv. Stress [MPa]

400
300
200
100
0
-0.2

-0.1

-100

0.1

0.2

0.3

0.4

-200
-300
Equiv. Strain
6120_T_00
6120_T_75
6120_S_45
6120_B_20

6120_T_15
6120_T_90
6120_S_60
6120_B_30

6120_T_30
6120_S_00
6120_S_75
DD3MAT_B_10

6120_T_45
6120_S_15
6120_S_90
DD3MAT_B_20

6120_T_60
6120_S_30
6120_B_10
DD3MAT_B_30

Results - EN AW-6120 T4
29

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Experimental and numerical equivalent stress-strain curves considering the

Hill 48 yield criterion and isotropic and kinematic work hardening

Equiv. Stress [MPa]

400
300
200
100
0
-0.2

-0.1

-100

0.1

0.2

0.3

0.4

-200
-300
Equiv. Strain
6120_T_0
6120_T_75
6120_S_45
6120_B_0_20

6120_T_15
6120_T_90
6120_S_60
6120_B_0_30

6120_T_30
6120_S_0
6120_S_75
DD3MAT_B_10

Results - EN AW-6120 T4
30

6120_T_45
6120_S_15
6120_S_90
DD3MAT_B_20

6120_T_60
6120_S_30
6120_B_0_10
DD3MAT_B_30

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Experimental and numerical equivalent stress-strain curves considering the

YLD 91 yield criterion and isotropic and kinematic work hardening
400
Equiv. Stress [MPa]

300
200
100
0
-0.2

-0.1

-100 0

0.1

0.2

0.3

0.4

-200
-300
-400
Equiv. Strain
6120_T_0
6120_T_75
6120_S_45
6120_B_0_20

6120_T_15
6120_T_90
6120_S_60
6120_B_0_30

6120_T_30
6120_S_0
6120_S_75
DD3MAT_B_10

6120_T_45
6120_S_15
6120_S_90
DD3MAT_B_20

6120_T_60
6120_S_30
6120_B_0_10
DD3MAT_B_30

Results - EN AW-6120 T4
31

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Springback evaluation Demeri Test

10
25

a) Drawn cup

c) Ring specimen

b) Ring cutting

d) Ring springback

Formability Analysis
32

Difference between the ring

diameters, before and after splitting,
gives a direct measure of the
springback effect

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Benchmark experimental apparatus

After the stamping operation

Final stage of the stamping operation

Formability Analysis
33

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DD3IMP

NUMERICAL SIMULATIONS PROCEDURE

Blank discretization

DD3TRIM

Full model used in the simulations

Formability Analysis
34

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Punch force during the stamping operations

90
80
70
Force [kN]

60
50
40
EXP EN AW-5182-H111

30

NUM EN AW-5182-H111

20

EXP EN AW-6120-T4

10

NUM EN AW-6120-T4

0
0

10

20

30

40

50

60

Displacement [mm]

Formability Analysis
35

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Springback results

Difference between the ring diameters, before and after splitting

Material
EN AW-5182-H111
EN AW-6120-T4

Experimental ring
opening
79.8 mm
46.8 mm

Formability Analysis
36

Numerical ring opening

87.4 mm
47.4 mm

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Independently of the constitutive model considered, the material parameter

identification error reported was always less than 5%.

For the EN AW-5182 alloy, the YLD91 criteria enable an accurate description
of the plastic behaviour of this alloy for all the testing directions.

For the EN AW-6120 alloy, none of the plasticity criteria enables the correct
description of the entire range of stress-strain curves. This can be related with
the strong variation of the plastic anisotropy coefficients in the sheet plane. A
more flexible criterion is needed to improve the description of the plastic
behaviour of this material.

The numerical program developed for the material parameter identification
tasks proved to be an efficient tool that can be used to select the best
phenomenological model.

 Conclusions
37