Material Characterisation Experiments and Data Preparation for a Finite Element Analysis of the Deep Drawing Process Using AA 1050-O

Abstract

The use of computer simulation to imitate physical processes has proven to be a time-efficient and cost-effective way of performing scenario testing for process optimisation in different applications. The finite element analysis (FEA) is the dominant numerical simulation method for analysing sheet metal forming processes. It uses mathematical tools and computer-aided engineering software programmes to predict forming processes. To improve the quality of output from the simulation, accurate material characterisation data that correctly model the behaviour of the material when it undergoes deformation must be provided. This paper outlines the stages of conducting material characterisation experiments, such as tensile, hardness, and formability tests, using the aluminium alloy AA1050-O. Sample preparation, the machine setup, and testing procedures for the material characterisation tests are given. Subsequent data preparation methods for input into an FEA software programme are also outlined. Implications of the testing results to a deep drawing process are examined while considering the formation of a rectangular monolithic component measuring 2300 mm by 1400 mm with a drawing depth of approximately 150 mm. The results from the characterisation tests indicate that the forming process for the product can be achieved using cold forming at room temperatures as a 25% strain was recorded before necking against an anticipated uniaxial strain of 5.93%. The aluminium alloy AA1050-O demonstrated a negligible strain rate sensitivity in the forming region, thus eliminating tool velocity from the key process parameters that should be considered during FEA simulations. A 50% increase in hardness was recorded after strain hardening.