Accurate sheet metal forming modeling for cost effective automotive part production

Abstract

Recent implementations of accurate material and tribology models in finite element codes for sheet metal forming process development have the potential to reduce development time and the associated development costs significantly. Adoption of new models requires validated material parameters and assessments of the overall accuracy. The paper presents a study aimed at accuracy estimation by comparing strain measurements and finite element simulation results for a laboratory flat bottom hole expansion test and an industrial automotive component produced at Volvo Cars. The use of the tensile test based Tata Steel Vegter yield locus model results in accurate prediction of dimensions and plastic deformation distribution in sheet metal forming applications.