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 expe rimental trials. For demonstration purposes, this procedure was used t o design a blank shape for a highly anisotropic aluminum alloy sheet ( 2090-T3) that results in a deep-drawn, circular cup with minimal earin g. All blank shape design methods require a certain number of iteratio ns. However, the sequential procedure can be more effective than the o ther iterative methods based on FEM analysis in conjunction with exper imental trials or on experimental trials alone. For this design demons tration, the anisotropic constitutive behavior of the 2090-T3 sheet wa s 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) 1 996 Elsevier Science Ltd.