42nd International Deep Drawing Research Group Conference - IDDRG 2023

The use of aluminium alloys with high mechanical properties is very interesting to reduce the weight of parts, especially in the automotive field. However, a formability problem prevents the use of these alloy at room temperature (RT), especially for complex shapes where part failure occurs before complete drawing. The use of a warm forming process, which consists of heating the part between 150°C and 250°C for aluminium alloys, allows to increase formability and therefore to perform complex shapes. In this study, forming of a cylindrical cup in 7075-T6 for temperatures ranging from RT to 200°C are simulated in Abaqus. Forming is performed in two steps by two reductions of the blank diameter. Numerical simulations show that the stresses and plastic strains in the cylindrical cup are higher than the material can withstand at 20°C, while at 200°C the stresses and plastic strains are acceptable, allowing the cup to be drawn in two stages.