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Prediction of Sheet Metal Formability (FLD) By Using Diverse Method

Article · January 2006

DOI: 10.1007/1-4020-5370-3_532

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 III European Conference on Computational Mechanics
Solids, Structures and Coupled Problems in Engineering
C.A. Mota Soares et.al. (eds.)
Lisbon, Portugal, 5–9 June 2006

PREDICTION OF SHEET METAL FORMABILITY (FLD) BY USING

DIVERSE METHOD
F. Abbassi1, 2, O. Pantale2, A. Zghal1 and R. Rakotomalala2
1
Laboratory of Mechanics, Solids, Structures and
Technological Development, ESSTT,
BP 56 Beb Mnara 1008, Tunis, Tunisia
abbassi.fethi@enit.fr
ali.zghal@esstt.rnu.tn
2
Laboratoire de Gnie Productique C.M.A.O., ENIT,
Avenue dAzereix-BP 1629, 65016 Tarbes Cedex, France.
(olivier.pantale, Roger)@enit.fr

Keywords: sheet metal; Forming Limit Diagram (FLD); formability; Hill's93 yield criterion;
local necking; diffuse necking, Swift hardening.

Abstract. In this paper we propose a procedure to evaluate the material formability based on
the use of a Forming Limit Diagram. FLD method is proven to be a useful tool in the analysis
of forming severity, it has been shown to be valid only for cases of proportional loading,
where the ratio between the principal stresses remain constant throughout the forming proc-
ess. In this works, quadratic and non quadratic Hill’s yield criterion are used to study the ma-
terial formability, we determinate the limit strain by using Hill’s 93 connecting with the Swift
and Hill necking condition in the case of material assuming a swift hardening low. And we
compare an empirical model proposed by NADDG between theatrical results.
 F. Abbassi, O. Pantalé, A. Zghal and R. Rakotomalala

1 INTRODUCTION
The Forming Limit Diagram (FLD) is a very good formability map [1], and the FLD offer
a convenient and useful tool in sheet products manufacturing analysis. Many methods are de-
veloped during the last past years for evaluating the sheet metal formability based on the FLD,
since the first intervention by Keeler and Backofen in 1964. Keeler and Backofen developed
the right side of the FLD (i.e., positive minor strain) [2], and Goodwin in 1968 [3] extended
the forming limit diagram to include the negative minor strain side. Several theoretical models
based on some plasticity theory were used in order to determinate the forming limit strains
and study the plastic instability. Furthermore, there are two types of necks in sheets: the dif-
fuse necking and the localized necking. The first criterion, proposed by Considère in 1885 [4],
is related to the maximum force. But this criterion allows only the study of diffuse necking in
the case of uniaxial tension; In 1952 Swift expanded the Considère criterion to calculate the
strain limit for diffuse necking in biaxial loading [5] when the major principal strain in an iso-
tropic case reaches the value:

εc =
( )
2 n 1 − α + α 2 ⋅ (2 − α )
(1)
4α 3 − 3α 2 − 3α + 4
where n is the hardening coefficient and α is the stress ratio.
The experiment shows that the formability of sheet is not limited by the appearance of dif-
fuse neck, for this reason, in the same year Hill developed a localized neck criterion [6].
The plasticity theory predicts the onset of necking and localized necking in the drawing re-
gion, but the localized necking cannot be determined by Hill theory in the biaxial tensile load-
ing range, which contradicts the experiments, thus Marciniak and Kuczynski in 1967
proposed their mathematical model for the theoretical determination of FLD, based on the ini-
tial geometric non-homogeneity of the material.

2 FORMABILITY ANALYSIS BY USING THE FLD

Formability, in sheet metal forming is usually related to the ability to account high values
of the strain until failure. This failure can become from local necking, fracture and wrinkling
[18]. The entire FLD of the sheet is determined by repeating the procedure for different de-
formation paths prescribed by the stress ratio α: from uniaxial tension α = 0, through a nearly
in-plane plane strain tension with α = 0.5, up to equi-biaxial tension for α = 1.
Marciniak and Duncan [19] schematize the defects on the FLD depending on the strain ra-
tion β = ε 2 ε 2 . where ε1 is the minor strain and ε2 is the major strain (figure 1).

Figure1. Illustration of the FLD given by Marciniak and Duncan and fracture mode variation
[18].

2
 F. Abbassi, O. Pantalé, A. Zghal and R. Rakotomalala

Two principal approaches are developed to study the material formability using FLD:
Experimental investigation, in order to obtain different ratios of biaxial strains. two types
of punch-stretching experiments by hemispherical punch and a flat-headed cylindrical punch
are performed. To plot the curve in the principal strain space, several methods are used to
measure the deformations such as the Grid Strain Analyses (GSA). This method is a two step
one: in the first step one print a circular or a square grid on the sheets before forming. The
second step is to measure the grid deformation in the deformed parts to determine the strains.
To improve the precision and to facilitate the determination of FLD, the use of optic technol-
ogy such as stereo-correlation based on the use of two CCD cameras becomes useful. This
means of advancing to allow the determination of cartography which describes the thinning
phenomenon.
Some mathematical models were used in order to calculate the sheet limit strains such as
diffuse necking by swift criterion, local necking by Hill condition and M-K model, the bifur-
cation analysis initially proposed by Hill (1952) and extended by Storen and Rice (1975) and
later by Hutchinson and Neale (1978) in conjunction with the use of deformation theory. The
perturbation technique for the prediction of forming limits was presented in 1988 by Dudzin-
ski and Molinari [19]. Mesrar et al [20] also proposed an analytical expression for the equiva-
lent strain for the positive and the negative minor in-plane strain region. This expression met
their M–K predictions with good accuracy.

3 STRAIN-STRESS RELATIONSHIP
The most widely used equations for representing the strain hardening behaviors in sheet
materials are:
n
Hollomon stress-strain relation: σ = K ε (2)
n
Swift stress-strain relation: σ = K (ε 0 + ε ) (3)
where K, n and ε0 are material parameters determined from experimental data. When the
equivalent stress depends only on the effective strain increment the Hollomon stress-strain
relationship follow quite well the material behavior [15].

4 HILL-SWIFT MODEL
For formability study many theoretical criteria are proposed. In this paper, the Hill-Swift
necking condition is used. Hill [6] assuming a narrow band in the sheet in which the strain
along the band direction becomes zero in case of localized necking:
1 d σ ∂f ∂σ 1 + ∂f ∂σ 2
<
σ dε ∂f (σ ,0) ∂σ (4)
In 1952 Swift exploited the Considère criterion to study the diffuse necking and proposed a
general Swift diffuse necking condition [5]:
1 dσ σ 1 (∂f ∂σ 1 ) 2 + σ 2 (∂f ∂σ 2 ) 2
⋅ <
σ d ε (σ 1 ∂f ∂σ 1 + σ 2 ∂f ∂σ 2 ) ∂f (σ ,0) ∂σ (5)
The determination of curve limits forming is performed by using the Hill necking criterion
in the left part of the space of principal deformation and the Swift criterion in the right part.
• Hill condition if ε2<0 (local necking)
A criterion of localized necking for the sheet metal laminates, in the negative strain region
is derived based on Hill’s theory of localized necking.

3
 F. Abbassi, O. Pantalé, A. Zghal and R. Rakotomalala

In a second form one can write equation 4:

dσ
= d ε ⋅ Z local
σ
(6)
Where the following expression for the sub-tangent of localized instability Zlocal is written:
∂f ∂σ 1 + ∂f ∂σ 2
Z local = (7)
∂f (σ ,0) ∂σ
• Swift condition if ε2>0 (diffuse necking)
In the second part of the FLD where the strain ratio β is positive, the diffuse criterion insta-
bility equation 3 has the equivalent form:
dσ
= d ε ⋅ Z diffuse (8)
σ
Where the sub-tangent of diffuse instability Zdiffuse expression is:
σ 1 (∂f ∂σ 1 ) 2 + σ 2 (∂f ∂σ 2 ) 2
Z diffuse = (9)
(σ 1 ∂f ∂σ 1 + σ 2 ∂f ∂σ 2 ) ∂f (σ ,0) ∂σ

4.1 Theoretical calculation of FLD by using Hill’48 Yield criterion:

After the isotropic yield criterion proposed by Von Mises, Hill in 1948 has proposed the
first anisotropic yield criterion. The classical quadratic yield criterion, Hill’48 present an ad-
vantage that explain its intensive use in sheet metal forming: only tree tensile tests at 0°, 45°,
90° are required to determine the material parameters. In plane case Hill’48 has the following
form:
σ = H ⋅ (σ x − σ y )2 + F ⋅ (σ y − σ z )2 + G ⋅ (σ z − σ x ) 2 + 2 ⋅ N ⋅ σ xy 2
(10)
2 2 2
2 f = (2 / 3)( F + G + H )σ = (G + H )σ 1 − 2 Hσ 1σ 2 + ( F + G )σ 2 = 1 (11)
2 2 2 2r
f = σ = σ1 + σ 2 + σ 1σ 2
(r + 1) (12)
Assuming that the stress-strain relation can be expressed using the Holloman equation and
connected the Hill’48 yield criterion with the instability condition.

If the strain ratio β >0 If the strain ratio β <0

 2r 
[1 + r (1 − α )].1 − α +α 2 
ε1 =  1+ r  1 + (1 − α )r
⋅n (13) ε1 = ⋅ n² (15)
 1 + 4r + 2r 2
2 (1 + α )
(1 + α )(1 + r ) 1 − α +α 
 (1 + r ) 2 
 2r 
[(1 + r ) α − r ].1 − α +α 2 
ε2 =  1+ r  ⋅n
(1 + r )α − r
(14) ε2 = .n
 1 + 4r + 2r 2
2 1+α (16)
(1 + α )(1 + r ) 1 − 2
α +α 
 (1 + r ) 

4
 F. Abbassi, O. Pantalé, A. Zghal and R. Rakotomalala

We used Swift-Hill model to determine the forming limit diagram presented in figure2. We
also illustrate the influence of the material parameters by using three different materials A
(r=1.06, n =2.88), B (r=2.385, n=0.215) and c (n=0.165, r =1.076).
Forming Limit Diagram

Material A
Material B
0,6 Material C
0,5
major strain

0,4

0,3
0,2

0,1

0
-0,4 -0,2 0 0,2 0,4
minor strain

Figure 2: Influence of strain hardening n and r-value of plastic anisotropy on FLD obtained by
Swift-Hill Model

4.2 Theoretical calculation of FLD by using Hill’93 yield criterion

Hill has proposed in 1993 a new yield criterion for orthotropic sheets metal [13].
The expression of the Hill's 1993 yield criterion is
σ 12 σ 1σ 2 σ 2 2  pσ 1 + qσ 2  σ 1σ 2
2
−c + 2
+  ( p + q) −  =1 (29)
σ0 σ 0σ 90 σ 90  σb  σ 0σ 90
c, p and q described by the relationship:
c 1 1 1
= 2
+ 2
+ (30)
σ 0σ 90 σ0 σ 90 σ b2
 1 1 1  2r (σ − σ 90 ) 2r90σ b c
 + −  p = 0 b 2
− 2
+ (31)
 σ 0 σ 90 σ b  (1 + r0 )σ 0 (1 + r90 )σ 90 σ0

 1 1 1  2r (σ − σ 0 ) 2r0σ b c
 + − q = 90 b 2
− 2
+ (32)
 σ 0 σ 90 σ b  (1 + r90 )σ 90 (1 + r0 )σ 0 σ 90
• Local necking (ε2<0)
The plastic function f is

1  2  σ u2   ( pσ 1 + qσ 2 )  
2f = σ
 1 
−  2 − σ 1σ 2 + σ 22 + ( p + q ) − σ 1σ 2  − 1 (33)
σ e2  σ b2  σb
    
The calculus of the derivatives of function f gives:

5
 F. Abbassi, O. Pantalé, A. Zghal and R. Rakotomalala

∂f  2 α 
= ξ = σ1  2 + ( p + q − c − t (2 p + qα )) (34)
∂σ 1 σ 0 σ 0σ 90 

∂f  2α 1 
= ω = σ1  2 + ( p + q − c − t ( p + 2qα ) ) (35)
∂σ 2  σ 90 σ 0σ 90 

∂f 1 cα α2
=η = − + + {( p + q ) − pt − αqt} (36)
∂σ σ 0 2 σ 0σ 90 σ 90 2
σ1
Where t =
σb
Using Levy-Mises equation of a material assuming a Swift hardening low,
∂f ∂σ 1 ∂f ∂σ 1
ε1 = ⋅n− ε0 (37)
∂f ∂σ 1 + ∂f ∂σ 2 ∂f ∂σ
ξ ξ
ε1 = ⋅n − ε0 (38)
ξ +ω η
ω ω
ε2 = ⋅n− ε0 (39)
ξ +ω η
• Diffuse necking (ε2>0)
Banabic and Dannemann [11] used Hill’s (1993) non-quadratic yield criterion in Swift’s
diffuse necking model connected with Hollomon hardening low and in the M–K model. For
several materials the law of Hollomon hardening low does not describe the σ / ε behaviour of
the metal. In this paper we connected the Swift stress-strain relationship a Swift- hill necking
condition, the expressions of the limits strain are:

2
 ∂f   ∂f  ∂f   ∂f 
σ 1   + σ 2     
 ∂σ 1   ∂σ 2  ∂σ 1   ∂σ 1 
ε1 = ⋅n − ε0 (40)
 ∂f 
2
 ∂f 
2
 ∂f 
σ 1   + σ 2    
 ∂σ 1   ∂σ 2   ∂σ 
2
 ∂f   ∂f  ∂f   ∂f 
σ 2   + σ 1     
 ∂σ 2   ∂σ 1  ∂σ 2   ∂σ 2 
ε2 = ⋅n − ε0
 ∂f 
2
 ∂f 
2
 ∂f 
σ 1   + σ 2    
∂σ
 1 ∂σ
 2  ∂σ 
(41)
In a second form one can write equation (41) and (42)
ξ ² + αξω ξ
ε1 = ⋅ n − ε0
ξ ² + αω ² η (42)

6
 F. Abbassi, O. Pantalé, A. Zghal and R. Rakotomalala

αω ² + ξω ω
ε2 = ⋅ n − ε0
ξ ² + αω ² η (43)
Mechanical parameters of an aluminum-killed steel [24] and Al6016-T4 aluminum [25]
n ε0 K (MPa)
σ 0exp (MPa)
σ 90exp (MPa)
σ bexp (MPa) r0exp r90exp

Al6016-T4 127 114 123.44 0.8 0.61 0.245 0.01 417.854

Aluminum-Killed Steel 205.8 204.1 242.9 1.950 2.318 0.237 0.02 520.2

Table 1: mechanical experimental parameters

0,6
Aluminum-skiled steel

0,5 Al6016-T4 Aluminum

0,4
Major Strain

0,3

0,2

0,1

0
-0,4 -0,2 0 0,2 0,4 0,6 0,8
Minor Strain

Figure 3: Theoretical FLD of aluminum-Killed steel and Al6016-T4 aluminum by using

Hill’93 yield criterion connected with Swift hardening law / Experimental and theoretical re-
sults (figure on the right published by [25]).

0,8 HILL'93 + Sw ift Hardinig (t=0,25)

HILL'93 + Sw ift Hardinig (t=1)
0,7 HILL'93 + Sw ift Hardinig (t=0,75)
HILL'93 + Sw ift Hardinig (t=0,5)
0,6
Major Strain

0,5

0,4

0,3

0,2

0,1

0
-0,6 -0,4 -0,2 0 0,2 0,4 0,6 0,8
Minor Strain

Figure 4: Influence of the t parameter upon the FLD

7
 F. Abbassi, O. Pantalé, A. Zghal and R. Rakotomalala

Figure 3 show the FLD of tow material computed by non quadratic yield criterion Hill’93,
on the right one finds a experimental and theoretical results of FLD of Al6016-T4 [25]. In
figure 4 we also illustrate the influence of the variation of FLD position according to the rela-
tion between σ1et σb.

5 NADDG EMPIRICAL MODEL

For the material assuming that the Hollomon stress-strain relationship North American
Deep Drawing Research Group (NADDG) proposed an empirical model to simplify the de-
termination of FLD. The equation for calculate the limit engineering strain in the plane-strain
state:
(23.3 + 14.13t 0 )n
ε 10 =
0.21 (44)
where t is the thickness of sheet and n the hardening coefficient.

IF Steel non coated( Hill-Swift)

0,8 IFsteel non coated (NADDG Model)
0,7 IF steel coated (Hill-Swift)
IF Steel Coated(NADDG model)
0,6
Sheet metal initial thickness(t0) n-value r-value
Major Strain

0,5
0,4
IF steel non
0,3 0.85 0.3443 1.877
coated
0,2
0,1
IF steel coated 0.85 0.2919 19726
0
-0,6 -0,4 -0,2 0 0,2 0,4 0,6
Minor strain

Figure 4. computed FLD using NADDG model Table 2. Normal anisotropy and strain hard-
and Hill-swift necking criteria ening exponent values [26]

6 CONCLUSION
Many theoretical and experimental methods are developed to determinate the FLD. In this
paper we use the Hill’s 93 and 48 yield criterion and we according with swift Hardening low.
A successuful correlation was observed between the theoretical results of FLD of the Al6016-
T4 by using Hill’s 93 and the experimental results published by Butuc and al. [25].
The NADDG model is an easy and rapid tool to predict the material formability and we
observe a good correlation with this empirical model and Hill-Swift necking condition.

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