Assessment of corner failure depths in the deep drawing of 3D panels usingsimplified 2D numerical and analytical models

Methodologies of rapidly assessing maximum possible forming heights are nee ded for three-dimensional (3D) sheet metal forming processes at the prelimi nary design stage. In our previous work, we proposed to use an axisymmetric finite element model with an enlarged tooling and blank size to calculate the corner failure height in a 3D part forming. The amount of enlargement i s called center offset, which provides a powerful means using 2D models for the prediction of 3D forming behaviors. In this work, an analytical beam m odel to calculate the center offset is developed. Starting from the study o f a square dap forming, a simple analytical model is proposed and later gen eralized to problems with corners of an arbitrary geometry. The 2D axisymme tric models incorporated with calculated center offsets were compared to 3D finite element simulations for various cases. Good assessments of failure height were obtained.