ESAFORM 2021 cup drawing benchmark of an Al alloy: Critical follow up analysis of its potentials

Abstract

Abstract. The 1st ESAFORM Benchmark, called EXACT [1], enabled an in-depth study of the factors that contribute to the accuracy of predictions and efficiency of finite element (FE) simulations of deep drawing of a cup from AA 6016-T4 sheet through the joint work of 11 teams. FE analyses were conducted with elasto-plastic models or crystal plasticity approaches using commercial or academic FE codes. This paper reminds the content of EXACT benchmark and gives new results that highlight the importance of the tool stiffness and various contact conditions to predict the ironing forces and the thickness distribution along the cup wall. The use of the Benchmark experimental data and virtual tests performed with DAMASK crystal plasticity code to identify and validate a two-surface kinematic hardening model based on Yoshida and Uemori approach is also discussed.