LAUSR

Aluminium sheet parts manufactured by cold-forming processes are subjected to ductile damage due to the plastic deformation. Tool design based on the experience and failure prediction using simple criteria in sheet metal forming can cause high cost of material scrap and tools modifications. Consequently, the ability to predict ductile damage gives full control of the forming process. This work was conducted to evaluate the predictive capability of different damage models for AA 5754 under cold forming condition. The models are calibrated using published tensile and forming limit diagram data for AA 5754. A set of experimental cup tests for AA 5754 sheet were conducted to validate the selected models. An FE model was developed to simulate the cup test process using LS-DYNA software. The selected models used were the Johnson-Cook, continuum damage model (CDM), Gurson model and the generalized incremental stress state-dependent model (GISSMO) model. The experimental results of the cup tests were compared with the simulation results from different damage models concluding that the Gissmo model was able to show a good agreement with the experimental results.