42nd International Deep Drawing Research Group Conference - IDDRG 2023

The range of blank-holding force (BHF) for which successfully forming of AA1100 in three different tempers is investigated using a combination of experiments and analysis. The experiments involve circular blanks of three different diameters: 35 mm, 37 mm and 40 mm. The thickness of the blanks is 0.51 mm. These are drawn with a punch of 20 mm diameter, i.e., at drawing ratios of 1.75, 1.85 and 2.0, respectively, using a custom, modular forming apparatus where the BHF can be controlled at will, between 0 and 2,400 N. The experiments are performed in an Instron 8872 servohydraulic frame, so that precise measurements of punch force and displacement are available. The working envelopes are determined experimentally in this way. It is found that grey zones exist between the wrinkling, safe and tearing regimes. These experiments are then simulated in Abaqus/Standard, using two types of models: axisymmetric and shell. In the latter case, plastic anisotropy is included using the Yld2000-2D anisotropic yield function. Wrinkling and tearing failure are induced using geometric imperfections: a circumferential random wave in the flange for the former (shell model) and a thickness reduction for the latter (axisymmetric and shell models). It is shown that the models are able to reproduce the experiments well. This serves as a verification of the modeling framework, so that is can be used for simulations of more complex forming.