Criteria for Determining Critical Thinning

in Stamped Components by Means of

LDHT and Simulation with MSC.Marc.
R&D Project PEMSA-UG

Dr. Eduardo Aguilera Gmez

M.Sc. Ismael Ruiz Lpez
Eng. Francisco Gerardo Seplveda Vera.

August 18th 2015

2015 Simulating Reality, Delivering Certainty Users Conference

 Abstract.

Sheet Metal Forming Process (SMFP) is very popular in the

automotive industry, almost all parts of chassis are obtained
by means of SMFP. In order to be more competitive these
process have been improved through out last years to
increase productivity. This situation has let the following
problem: produce more parts in less time means that more
parts with cracks can also be produced. This study show
how PEMSA, by means of Limit Dome High Test with
Nakazima samples and simulation with MSC.Marc can set a
reliable failure criteria based on numerical and experimental
Forming Limit Curves to assure quality on stamped parts.

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 Index
01 Problem definition.
02 Mechanical characterization.
03 Limit Dome Height Test (LDHT) with Nakazima samples.
04 Finite element modeling of LDHT with MSC.Patran.
05 Correlation between physical tests and simulation.
06 Determination of forming limit curve (FLC).
07 Comments and Conclutions.
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Problem Definition.
Problem Definition.

There are two main failure modes during SMFP:

1. Fracture.
2. Wrinkling.

Wrinkles
Crack

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Problem Definition.

Formability criteria shall covers both failure cases wrinkles

and fractures.

In SMFP formability criteria are based on plane states of

deformation.

Fracture can starts when

Wrinkling tendency starts
major strain in on tensile
when major strain is
and excessive thinning
compressive.
occur.

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Problem Definition.

One of the most popular failure criteria in SMFP are based

on Forming Limit Diagram (FLD).
FLC can be obtained by means of LDHT and Nakazima
samples.
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Problem Definition.

Universal Drawing Machine

Holding Cylinders

Tool of Limit Dome Height Test (LDHT)

Holder

Tool

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 Problem Definition.

Obtaining FLC by means of LDHT has, by its own nature,

the following problems:

1. The test need to be stopped before necking appear.

2. The test shall be frictionless.

Maximum
thinning shall
appear at the
top of the
dome.

Necking and fracture are

in a dome crown.

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Problem Definition.
BEGINING

TO DEFINE STAMPING COMPONENT

TO GET MATERIAL SAMPLES FOR MECHANICAL CHARACTERIZATION

UNIAXIAL TENSILE TESTS LDHT NAKAZIMA SAMPLES

hMIN, FLOW CURVE, FAILURE

3 PEMSA MATERIAL MODE
DATA BASE

FINITE ELEMENT MODELLING OF LDHT

2 MATERIAL PROPERTIES, YIELD LOCUS, FRICTION
VALUE AND MODEL, MESH STRATEGY, hMIN

1
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Problem Definition.
1

NO SIMULATION
2 CORRELATES
WITH TEST
YES

RUN FRICTIONLESS LDHT SIMULATION

max, min, THINNING

3 DETERMINATION OF FLC

DETERMINATION OF MAXIMUM PERMISIBLE THINNING BY MEANS OF

FLC AND CIRCLE GRID.

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Mechanical Characterization.
Mechanical Characterization.

An Advanced High Strength Steel (AHSS) class type 590

Dual Phase Steel (DP590) @ 1.6 mm of thickness has been
chosen for study.

Tensile Samples at 045and 90from Rolling direction

has been taken from raw material in order to get the
following mechanical properties:

Elastic modulus [E] at 0

Yield strength at 045and 90
Anisotropic cocients or r-values at 045 and 90
True plastic strain-stress curve
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Mechanical Characterization.
Test direction
0 45 90
y [MPa] 415.4 320.9 424.8
n 0.1903 0.2001 0.1821
K [MPa] 1039.68 900.74 1054.63
r 1.26 1.24 1.27
E [MPa] 212950 190862 206585

800

700

600
True Stress [MPa]

500

400

300

200

100
YRDIR(1)= 1.12118758
0
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18
True Strain [mm/mm] YRDIR(2)= 1.1465587
YRDIR(3)= 1.19330761
YRDIR(1)= 1.12118758 YRSHR(1)= 1.10757644
YRDIR(2)= 1.1465587 YRSHR(2)= 1
YRDIR(3)= 1.19330761 YRSHR(3)= 1
YRSHR(1)= 1.10757644
YRSHR(2)= 1
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Limit Dome Height Test with Nakazima
Samples.
Limit Dome Height Tests with Nakazima Samples.
Samples before LDHT`s.

Square sample. 75 mm wide sample.

50 mm wide sample. 25 mm wide sample.

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Limit Dome Height Tests with Nakazima Samples.
Samples after LDHT`s.

hmin= 32.0 mm. hmin= 29.4 mm.

hmin= 28.0 mm. hmin= 26.4 mm.

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Finite Element Modelling of LDHT with
MSC.Patran.
 Finite Element Modelling of LDHT with MSC.Patran
Components layout.
Clearance between upper and lower
die is 6.7 mm, so upper die
Upper die displacement is 5.1 mm.
Rigid body

Sample
Deformable body

Lower die
Rigid body.

Punch
Rigid body

Clearance between sample and lower die

before gravity step is 0.05 mm.
Clearance between upper die and sample
before gravity step is 0.1 mm.
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Finite Element Modelling of LDHT with MSC.Patran
Mesh strategy.

Square sample 75 mm wide sample

3872 elements 2624 elements

50 mm wide sample 50 mm wide sample

2813 elements 4498 elements
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Finite Element Modelling of LDHT with MSC.Patran
Mesh strategy.
Element 139 from MSC.Marc Library.

Four-node, thin-shell element.

Four inner Gauss points and bilinear

interpolation.

Comprises of five layers as well as some

elements used by other special purposes
software.

Less expensive than others high order shell

elements, and therefore very attractive in non-
linear analysis.

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Finite Element Modelling of LDHT with MSC.Patran
Load cases.

Three load cases are defined in analysis:

1. Gravity. To allow sample to start contact with lower die.

2. Holding. To full restrain sample between lower and upper
die and to pure stretching during LDHT.
3. Drawing. To get plane strain at the top of the dome of
sample after LDHT.

Movement between tooling and sample are governing by

kinematics (velocity) for each load step and affects upper die
and punch.

Gravity are independent of time, so it acts over sample

during all simulation.
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Finite Element Modelling of LDHT with MSC.Patran
Movement control based on velocity field.

Velocity Fields for Punch & Holder

35
32
30 29.4
28
26.4
Velocity [mm/s] 25

20 Holder
Square sample
15 75 mm sample
50 mm sample
10
25 mm sample

5 5.1

0
0 1 2 3
Time [s]

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Finite Element Modelling of LDHT with MSC.Patran
MSC.Marc preferences.

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Finite Element Modelling of LDHT with MSC.Patran
Summary status of iterations.

.
.
.

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Correlation between physical tests and
simulation.
 Correlation between physical tests and simulation
Square sample Thickness results [mm].

punch= 32.0 mm
coulomb=0.15
tminimum=1.05 mm [numerical]
tminimum= [test]

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 Correlation between physical tests and simulation
75 mm wide sample Thickness results [mm].

punch= 29.4 mm
coulomb=0.15
tminimum=1.21 mm [numerical]
tminimum= 1.237 mm [test]
Error= 2.18%

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 Correlation between physical tests and simulation
50 mm wide sample Thickness results [mm].

punch= 28.0 mm
coulomb=0.15
tminimum=1.32 mm [numerical]
tminimum= 1.347 mm [test]
Error= 2.00 %

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 Correlation between physical tests and simulation
25 mm wide sample Thickness results [mm].

punch= 26.4 mm
coulomb=0.15
tminimum=1.26 mm [numerical]
tminimum= 1.322 mm [test]
Error= 4.68 %

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Determination of Forming Limit Curve.
Determination of Forming Limit Curve.
Square sample frictionless- major and minor strains results.

max = 3.798e-1 min = 2.288e-1

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Determination of Forming Limit Curve.
75 mm wide sample frictionless- major and minor strains results.

max = 2.667e-1 min = -6.191 e-2

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Determination of Forming Limit Curve.
50 mm wide sample frictionless- major and minor strains results.

max = 3.194 e-1 min = -1.082 e-2

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Determination of Forming Limit Curve.
Goodwin Portion 75 mm & 50 mm Samples.

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Determination of Forming Limit Curve.
Keeler Portion Square Sample.

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 Determination of Forming Limit Curve.

Marginal zone
Failure zone

Marginal zone

Safe zone

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Comments and Conclusions.
Comments and conclusions.

This research is a part of the project named Implementacin

Integral de Mtodos para la Caracterizacin de Aceros
Avanzados de Alta Resistencia para la Industria Automotriz.
jointly developed with Guanajuato State University and partial
financial support of the Guanajuato State Council of Science
and Technology (CONCyTEG).

PEMSA is the only one Company in Mexico that has the

capability of obtain FLC of sheet metal since 2011, witch has
represented a technological advantage.

Now, with this new methodology PEMSA can reduce effort, test
time, avoid use of specialized optical equipment and therefore
reduce several laboratory costs.

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Comments and conclusions.

Next steps in this research are:

To get three additional FLCs of three Advance High Strength

Steels (AHSS) selected in order to complete one of the
Project objectives.

By means of simulation PEMSA can design additional

Nakazima geometries in order get more data points in the
FLC.

To stablish thinning criteria by means of obtaining FLC and

circle grid techniques.

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