Simulation of Aluminium Sheet Metal Deep Drawing at Elevated Temperatures using LS-DYNA

A disadvantage of aluminium is that it is less formable than steel. One method for overcoming this disadvantage is deep drawing at elevated temperatures. In this way the formability of aluminium sheet metal can be improved significantly. This paper introduces deep drawing of aluminium sheet metal at elevated temperatures, a corresponding simulation method, a characteristic process and its optimization. The temperature and strain rate dependent material properties of a 5xxx series alloy and their modelling are discussed. A three dimensional thermomechanically coupled finite element deep drawing simulation model and its validation are presented. Based on the validated simulation model the process is optimized regarding formability and cycle time. The optimization focuses on the temperature distribution of the tooling and the blank, the punch velocity and the blank holder force.

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