Blank shape design for a planar anisotropic sheet based on ideal forming design theory and fem analysis

A sequential design procedure to optimize sheet forming processes was developed utilizing ideal forming design theory, FEM analysis and experimental trials. For demonstration purposes, this procedure was used to design a blank shape for a highly anisotropic aluminum alloy sheet (2090-T3) that results in a deep-drawn, circular cup with minimal earing. All blank shape design methods require a certain number of iterations. However, the sequential procedure can be more effective than the other iterative methods based on FEM analysis in conjunction with experimental trials or on experimental trials alone. For this design demonstration, the anisotropic constitutive behavior of the 2090-T3 sheet was expressed using plastic potentials previously proposed by Barlat et al. The implementation of the anisotropic strain-rate potential in the ideal forming design code is also briefly summarized. Copyright (C) 1996 Elsevier Science Ltd.