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FEM Simulation of Non-Axisymmetric Stretch Flange Forming of Aluminum Alloy 5052 Based On Shell Type Elements PDF
FEM Simulation of Non-Axisymmetric Stretch Flange Forming of Aluminum Alloy 5052 Based On Shell Type Elements PDF
4, December 2017
Abstract: Finite element simulation of stretch flanging process was carried out in order to investigate the effect of
process parameters on maximum thinning (%) in stretch flanging process. Influences of initial flange length, punch die
clearance, width of sheet metal blank and blank holding force were investigated on maximum thinning (%). Finite
element simulation was done using FEM software package ABAQUS. Sheet metal blanks of AA 5052 were utilized for
numerical simulation of stretch flanging process. Mesh convergence study was carried out to ascertain the accuracy
of present FEM model. It is found that circumferential strain and shell thickness decreases with decrease in initial
flange length and punch-die clearance while both decreases with increase in blank-holding force. Radial strain
increases with decrease in initial flange length and punch-die clearance and with increment in blank-holding force and
width of sheet. It is found that width of sheet metal blank and blank holding force have greater influence on maximum
thinning (%) as compared to initial flange length and punch die clearance.
69
Y. Dewang, M. S. Hora and S. K. Panthi
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Iranian Journal of Materials Science & Engineering Vol. 14, No. 4, December 2017
meshed FEM model meshed of die consists of the elements and 7952 nodes. The blank-holder is
following dimensions: radius of die = 35 mm, 30 then allowed to move in the vertical direction to
mm, 25 mm & 20 mm, height of die = 80 mm, accommodate changes in the blank thickness.
fillet radius at all radii = 5 mm. Meshing of die is The friction coefficient of 0.1 was defined
done with a 3D shell type feature which consists between different contact surfaces. The die
of R3D4 discrete rigid element type. It has 2734 remains fixed in all direction while sheet was
elements and 2785 nodes. It is meshed by free allowed as a free body which was controlled by
meshing technique. Another meshed model is of the contact boundary condition between the
punch which has dimensions: radius of punch=30 different tools and sheet. The punch movement
mm, height of die = 55 mm, fillet radius = 5 mm. was defined using a pilot node. This node is
It is a shell type feature which consists of 4429 employed to obtain the punch force to bend the
R3D4 quadrilateral discrete rigid elements and sheet during simulation. Punch was allowed to
4485 nodes. Blank holder has dimensions in move only in downward direction while it was
terms of radius as 20mm, 25mm, 30 mm and 35 constrained in all other direction. Finite element
mm. It is also discretized using 448 R3D4 simulations are done using radius of die and
discrete rigid elements and 492 nodes. holder=30 mm in the present study.
Dimensions of sheet metal blank are as: length of
sheet metal blank = 100 mm, width of sheet metal 2. 1. 2. Mesh Sensitivity & Convergence Analysis
blank = 50 mm, thickness of sheet metal blank =
0.5 mm. The blank of AA 5052 is considered as In order to evaluate the sensitivity of mesh,
deformable entity. The blank is modeled using a five different mesh sizes are considered namely
4-node doubly curved thin shell element with 40*40, 50*40, 60*40, 70*40 and 80*40 as shown
reduced integration, S4R finite strain elements in Fig. 2. The mesh converengence is evaluated
having 5 integration points through thickness. It in terms of output parameters such as radial
consists of 7770 S4R quadrilateral discrete rigid strain, circumferential strain, von-Mises stress,
Fig. 2. Different mesh sizes for the mesh sensitivity and convergence (a)40*40 (b)50*40 (c)60*40 (d)70*40 (e)80*40
71
Y. Dewang, M. S. Hora and S. K. Panthi
250
von Mises stress (N/mm2)
200
̊˹*̊˹
150
̊˹*̋˹
100 ̊˹*̌˹
̊˹*̀˹
50
̊˹*́˹
0
Ͳ ͷ ͳͲ ͳͷ ʹͲ ʹͷ
True distance along free edge near to sheet center (mm)
flange thickness. Table 2 shows the mesh elements used is known as S4R. It is used for
convergence study data with total computational discretization of blank of Aluminum alloy in
time. It clearly indicates that convergence is FEM analysis. S4R is a 4-noded quadrilateral
obtained for the partitioned mesh size 60*40 with element with reduced integration rule with one
lesser computational time. Figure 3 shows that integration point. It is robust and generally used
the von mises stress converged for the mesh size for a wide range of applications. This element is
of 60*40 and 70*40. That is why, 60*40 mesh present in commercial software package
size is selected out of 70*40 mesh size, as it ABAQUS and based on thick shell theory. It
involves less number of elements and less considers finite-strain formulation and thus can
computational time at the expense of reasonable be used to perform large strain analyses. It has
accuracy. In this way as the all the output the feature of uniformly reduced integration to
parameters converges for the mesh size 60*40. avoid shear and membrane locking. It converges
Therefore for this mesh size 60*40, mesh to shear flexible theory for thick shells and
convergence is reported. classical theory for thin shells. Fig. 4 shows the
four node shell element (S4R).
2. 1. 3. Finite Element Modeling with Shell It is a 3D shell type feature which consists of
Elements R3D4 discrete rigid element type. It has 2734
elements and 2785 nodes and is meshed by free
This section describes the development of meshing technique. It is a shell type feature
finite element model for non-axisymmetric which consists of 448 R3D4 discrete rigid
stretch flanging process using shell type elements and 492 nodes. It is meshed by free
elements. In the current work, one of the shell meshing technique. Punch is meshed with shell
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Iranian Journal of Materials Science & Engineering Vol. 14, No. 4, December 2017
Fig. 4. A 4-node (S4R) shell element type Fig. 5. Finite element model for stretch flanging process
0.07
400 N 0.005
0.06
0
Circumferential strain
600 N
0.05
500 N -0.005 0 10 20
Radial strain
Fig. 6. Effect of blank holding force on radial strain Fig. 7. Effect of blank holding force on circumferential
strain
73
Y. Dewang, M. S. Hora and S. K. Panthi
Radial strain
0.494 0.04
0.492 0.03
0.49 0.02
0.488 0.01
0.486 0
0.484
-0.01 0 5 10 15 20
0 5 10 15 20
True distance along free edge upto True distance along free edge upto punch
punch center center
Fig. 8. Effect of blank holding force on flange thickness Fig. 9. Effect of initial flange length on radial strain
force. The circumferential strain is found to be thickness varies non-linearly from free edge of
maximum at free edge of blank and minimum at flange to sheet center. The minimum flange
the centre of sheet metal blank for all cases. The thickness is obtained at the center of sheet. The
contributing factor here for the increment of greater will be the blank holding force the higher
circumferential strain along free edge of blank is will be the reduction in flange thickness at center
the coefficient of friction which act between of sheet. The reduction in flange thickness is
blank, die, blank holder and punch. Upon occurring due to the effect of the blank holding
increment of blank holding forces the force as greater will be the blank holding force,
circumferential strain increases in which friction the effect of coefficient of friction also
coefficient helps in holding and forming the contributes for reduction in flange thickness.
stretch flange with greater induced
circumferential strain. 3. 2. Effect of Initial Flange Length
Fig. 8 shows the variation of flange thickness
along free edge of stretch flange upto punch This section presents finite element simulation
center for different blank holding forces of results pertaining to the effect of initial flange
constant intensity. It is found that the flange length on output parameters such as radial strain,
Flange length = 20 mm
Flange length = 20 mm Flange length = 30 mm
0.005 0.502
Flange length = 30 mm Flange length = 40 mm
Flange thickness (mm)
)
0.5
Circumferential strain
Flange length = 40 mm
0
(
0 5 10 15 20 0.498
-0.005 0.496
hi k
-0.01 0.494
0.492
-0.015
l
0.49
-0.02 0.488
-0.025 0.486
0 10 20
-0.03 True distance along free edge upto punch True distance along free edge upto
center punch center (mm)
Fig. 10. Effect of initial flange length on circumferential Fig. 11. Effect of initial flange length on flange thickness
strain
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Iranian Journal of Materials Science & Engineering Vol. 14, No. 4, December 2017
circumferential strain and flange thickness. It is reduces along free edge to sheet center. This
found form Fig. 9 and Fig. 10 that circumferential might be occurring due to the increment in initial
strain increases while radial strain decreases with flange length as result of which for a given blank
increase in initial flange length. It is also holding force, the reduction in flange thickness
noticeable that the maximum radial strain and the will be less as more amount of blank holding
maximum circumferential strain are obtained at force will be required to hold it and then to
the sheet center and corner edge of flange further deform it, to obtain change in thickness of
respectively. The increment in circumferential flange and lower will be the initial flange length,
strain and decrement in radial strain along free higher will be reduction in flange thickness along
edge of sheet upto sheet center is due to free edge to sheet center. Therefore higher will be
increment in initial flange length. The increase in the initial flange length, the reduction in
initial flange length corresponds to the thickness will be lesser.
availability of greater amount of length for
deformation and hence greater contact area is 3. 3. Effect of Punch-Die Clearance
available due to which the circumferential strain
increases and radial strain decreases along free This section presents finite element simulation
edge of sheet to sheet center. The greater degree results that represent the effect of punch -die
of deformation and increment in circumferential clearance on output parameters, such as-radial
strain and decrement in radial strain is also due to strain, circumferential strain, flange thickness.
coefficient of friction. Therefore the Fig. 12 and Fig. 13 shows the effect of punch-die
circumferential strain increases and radial strain clearance on radial strain and circumferential
decreases along free edge and maximum strain. It is found that radial strain decreases
circumferential strain and maximum radial strain while circumferential strain increases with
is found at corner of flange. increment of punch-die clearance. The maximum
Fig. 11 shows the effect of initial flange length radial strain and the maximum circumferential
on flange thickness. It is found that that the flange strain are obtained at the center of sheet and free
thickness varies non-linearly along the free edge. edge of sheet. It is noticeable that little decrement
The flange thickness is found maximum at the in circumferential strain is observed at free edge
corner of the free edge while minimum at the with increase in punch-die clearance while a
center of the free edge for all initial flange length considerable decrement is observed in
values. It is found that with increase in initial circumferential strain with increase in punch-die
flange length results in diminishing flange clearance at centre of sheet. The circumferential
thickness variation. Upon increment of initial strain and radial strain both decreases with
flange length the reduction in flange thickness increase in punch die clearance because with
0.005
0.05
Circumferential strain
Clearance=0.5mm 0
0.04 Clearance= 0.75 mm 0 5 10 15 20
-0.005
Radial strain
0.03 Clerance= 1 mm
-0.01
0.02
0.01 -0.015 Clearance= 1 mm
Clearance=0.75 mm
0 -0.02 Clearance= 0.5 mm
0 5 10 15 20 True distance along free edge upto punch
-0.01 -0.025
True distance along free edge upto punch center
center
Fig. 12. Effect of punch-die clearance on radial strain Fig. 13. Effect of punch-die clearance on circumferential
strain
75
Y. Dewang, M. S. Hora and S. K. Panthi
0.502
0.5 Width of sheet = 40 mm
Flange thickness (mm)
Width of sheet = 50 mm
0.18 Width of sheet = 60 mm
0.498 0.16
0.496 0.14
Radial strain
0.12
0.494 0.1
Clearance=0.5 mm 0.08
0.492
Clearance=0.75 mm 0.06
0.49 0.04
Clearance=1 mm 0.02
0.488 0
0 5 10 15 20 0 10 20 30
True distance along free edge upto punch
True distance along free edge upto sheet
center (mm)
center
Fig.14. Effect of punch-die clearance on flange thickness Fig.15. Effect of width of sheet metal blank on radial strain
increase in punch die clearance the gap between strain and circumferential strain distribution
the punch and sheet for deformation increases along free edge of sheet. It is found that radial
which actually decreases the effective force strain and circumferential strain increases non-
which is required to form the stretch flange. The linearly with increase in the width of sheet. It is
lesser will be the punch-die clearance the higher important to notice that the maximum radial
will be the radial strain and circumferential strain strain and the maximum circumferential strain
at sheet center and corner edge of flange are obtained for largest width of sheet. The
respectively. Again here, coefficient of friction maximum radial strain is found at center of sheet
also plays role in stretch flange forming. Fig. 14 while maximum circumferential strain occurs at
shows the effect of punch-die clearance on flange the corner edge of sheet. The increment in radial
thickness. It is found that flange thickness varies strain as well as in circumferential strain along
non-linearly along the free edge of blank. The free edge of sheet with increase in width of sheet
flange thickness is found maximum at the corner is occurring due to increment in width of sheet
of flange while it is minimum at the center of the because the sheet with greater width provides the
sheet. The reduction in flange thickness along chances of greater degree of deformation. The
free edge to sheet center decreases with increase
in punch die clearance. This might be occurring
due to the fact that higher will be the punch die
Width of sheet = 40 mm
clearance the reduction(change) in flange 0.01 Width of sheet = 50 mm
thickness will be lower because the combined 0 Width of sheet = 60 mm
effect of given blank-holding force and -0.01 0 10 20 30
Circumferential strain
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Iranian Journal of Materials Science & Engineering Vol. 14, No. 4, December 2017
0.495 7.56
Percentage thinning
7.54
0.49 7.52
(maximum)
0.485 7.5
0.48 7.48
7.46
0.475 7.44
0.47 7.42 Width of sheet =
7.4 40 mm
0.465
7.38
0.46 20 30 40 50
0 10 20 30
Initial Flange Length (mm)
True distance along free edge upto sheet
center (mm)
Fig. 17. Effect of width of sheet metal blank on flange Fig. 18. Effect of initial flange length on percentage of
thickness thinning(maximum)
lesser will be width of sheet, it is rather difficult die clearance, blank-holding force and width of
to deform it into flange as well as the strain blank on percentage of thinning (maximum). The
induced after flange formation will also be less. percentage of thinning (maximum) can be
The combined effect of blank holding force and computed with usage of simplified formula as:
coefficient of friction also plays important role as
well. Therefore the radial strain and Percentage of thinning (maximum)= ((Final
circumferential strain both increases with thickness of blank-Initial thickness of blank))
increment in width of sheet. /(Initial thickness of blank)
Fig. 17 shows the effect of width of blank on
flange thickness variation. It is found that the Percentage of thinning (maximum) for
flange thickness increases with increase in the different process parameters is shown in Table 3.
width of blank at corner edge of flange. The Fig.18 to Fig. 21 shows the effect of process
minimum flange thickness value is obtained for parameters such as initial flange length,punch-die
the least sheet width. The flange thickness of 50 clearance,blank-holding force and width of blank
mm and 60 mm sheet width values are pretty on percentage of thinning (maximum)
close to each other and far apart from their respectively.
corresponding values for the sheet width of 40 It is found from the figures that percentage of
mm. Besides this, it is also found that the thinning increases with increase in initial flange
reduction in flange thickness along free edge up
to punch center is found to increase with increase
in width of sheet. The minimum thickness for the Width of sheet blank = 40 mm
7.65
Percentage thinning
This section describes the effect of different Fig. 19. Effect of punch-die clearance on percentage of
thinning(maximum)
process parameters such as initial length, punch-
77
Y. Dewang, M. S. Hora and S. K. Panthi
Percentage thinning
7.2 10
(maximum)
7.15
(maximum)
9
7.1
8
7.05
7
7
6.95 6
6.9 5
400 450 500 550 600 40 50 60
Blank-holding Force (N) Width of sheet metal blank (mm)
Fig. 20. Effect of blank - holding force on percentage of Fig. 21. Effect of width of blank on percentage of
thinning thinning(maximum)
length, blank-holding force and width of blank clearance is basically occuring due to the
whereas it decreases with increase in punch-die combined effect of coefficient of friction in
clearance. Out of these four process parameters, conjuction with these process parameters such as
width of blank is the most dominating parameter width of blank, initial flange length and blank
which significantly influence the percentage of holding force. The percentage of thinning
thinning (maximum). The higher is the width of decreases with increase in punch-die clearance as
blank, initial flange length and blank holding in this the effect of coefficient of friction
force, greater will be the percentage thinnning diminishes. Therefore, coefficient of friction
(maximum) in stretch flange. The increment in plays an important role again here in increment
percentage of thinning with increment in the as well as decrement in perecentage thinning in
width of blank, initial flange length and blank stretch flange. Fig. 22 shows the typical contour
holding force and decrement in punch-die plots of percentage of thinning for initial flange
78
Iranian Journal of Materials Science & Engineering Vol. 14, No. 4, December 2017
(a) (b)
(c) (d)
Fig. 22. Effect of process parameters on percentage of thinning (maximum) (a) initial flange length (L= 50 mm) (b) punch-
die clearance (c = 0.75 mm) (c) blank-holding force (BHF = 600N) (d) width of blank (w = 60 mm)
length (L=50 mm), punch-die clearance (c=1 sheet using finite element analysis. Mesh
mm), blank-holding force (BHF = 600 N) and convergence study has been carried out to
width of blank (w=60 mm) resepectively. It is ascertain the accuracy of present FEM results.
clear from the contour plots that maximum Width of sheet is found to be major parameter
thinning occurs when the blank is bending into which significantly affects the formability of
die because as the blank is bending into die, stretch flanging process. It is found that
circumferential tensile stresses are generated maximum thinning (%) increases approximately
along die profile radius, which are greatest at the by 38 % with increase in width of sheet. The
edge of sheet. Therefore maximum thinning is greater the width of sheet, higher will be the
reported at edge of sheet due to bending of blank change in thickness at the end of flange. Initial
into die. flange length has a negligible effect on maximum
thinning (%) as it increases only by 2% with
4. CONCLUSIONS increase in initial flange length. Punch-die
clearance also has a negligible effect on
This paper presents the effect of process maximum thinning (%) as it decreases by 3 %.
parameters such as initial flange length, punch- Blank holding force has a reasonable effect on
die clearance, blank holding force and width of maximum thinning (%), as it increases by 5%
79
Y. Dewang, M. S. Hora and S. K. Panthi
with increase in blank holding force. There are Process. Technol., 2004, 145(1), 93–98.
number of parameters in stretch flanging process 5. Li, D., Luo, Y., Peng, Y. and Hu, P., “The
which still need to be studied. In the present numerical and analytical study on stretch
analysis, constant blank holding forces are flanging of v-shaped sheet metal”. J. Mater.
utilized. The following are the major outcomes of Process. Technol., 2007, 189(1-3), 262–267.
research work: 6. Yeh, F. H., Wu, M. T. and Li, C. L., “Accurate
optimization of blank design in stretch flange
- The circumferential strain and shell based on a forward–inverse prediction scheme”
thickness decreases with decrease in initial Int. Mach. Tool. Manu., 2007, 47(12-13), 1854–
flange length while radial strain increases 1863.
with decrease in initial flange length. 7. Chen, Z., Worswick, M. J., Pilkey, A. K. and
- The circumferential strain and shell Lloyd, D. J., “Damage percolation during
thickness decreases, with decrease in stretch flange forming of aluminum alloy
punch-die clearance whereas radial strain sheet”. J. Mech. Phys. Solids., 2015, 53(12),
increases with decrease in punch-die 2692-2717.
clearance. 8. Butcher, C., Chen, Z. and Worswick, M., “A
- The circumferential strain and shell lower bound damage-based finite element
thickness decreases with increase in blank- simulation of stretch flange forming of Al–Mg
holding force while radial strain increases alloys”. Int. J. Frac., 2006, 142(3-4), 289-298.
with increase in blank-holding force. 9. Simha, C. H. M., Grantab, R. and Worswick, M.
- The radial strain increases with increase in J., “Application of an extended stress-based
width of sheet along free edge up to centre forming limit curve to predict necking in stretch
of the sheet while circumferential strain flange forming”. J. Manuf Sci E-T ASME,
decreases with increase in width of sheet. 2008, doi:051007-1- 051007-11(2008).
- The maximum percentage of thinning 10. Dewang, Y., Hora, M. S. and Panthi, S. K.,
increases with increase in initial flange “Finite element analysis of non-axisymmetric
length, blank-holding force, width of sheet stretch flanging process for prediction of
while it decreases with increase in punch- location failure”, Procedia Materials Science 5,
die clearance. 2014, 2054-2062.
11. ASTM E8/E8M-11(2011), “Standard test
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