Simulation Of The Deep Drawing Of Aluminum Sheet Using Crystal Plasticity FEM

The anisotropy of sheet metal exerts an evident influence on the formability. In recent years, great progress has been made in how to introduce anisotropy parameters into the plasticity finite element analysis of sheet metal forming.In order to satisfy increasing request of the automobile light-weight, many kinds of light-weight material have being studied and developed. Comparing with the steel sheet, the aluminum alloy sheet has small density, high strength, corrosion resistance and so on, and therefore can satisfy the special request of the automobile light-weight. Aluminum alloys have become the principal materials that substitute steel sheet in the automobile light-weight technology. Because of the difference of crystal structure, the traditional forming theory and technology of steel sheet can not be directly used in forming of the aluminum alloy sheet, and we need to explore new forming theory and technology that are suited to the aluminum alloy sheet used in automobile.The deep drawing of 5A02 aluminum sheet was experimentally investigated, and further in the framework of rate-dependent crystal plasticity theory, the deep drawing process was numerically simulated by crystal plasticity finite element method (CPFEM). The earing phenomenon and the variation of sheet thickness were studied, and the evolution of the maximum and minimum thickness during the drawing process was discovered. The effects of the friction coefficient and the blank holding force on the earing profile were studied, and further the limit drawing coefficient of 5A02 aluminum sheet was also obtained. The predictions from the CPFEM simulations are found in reasonable agreement with the experimental results, which include the height of the earing profile and the value of the limit drawing coefficient, increasing friction coefficient or blank holding force will enable increasing height of the earing profile.