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Transfer project T-A2: Micromechanical modeling and simulation of forming processes

Person in Charge: Dipl.-Ing. Vedran Glavas

Motivation and objectives:
Within the frame of  research training group 1483, the transfer project applies current research topics to industrial problems. The industrial cooperation partner is Constellium, one of the leading companies for aluminum alloys worldwide.
In many cases, phenomenological material models do not provide satisfying results in the forming process of polycrystalline materials. The underlying large deformations and their influence on the evolution of the microstructure may not be neglected. A two scale constitutive model is used for the forming simulations with crystal plasticity material behavior on the micro scale.

Investigations  Results
The beverage can manufacturing process is the first problem considered. A circular blank out of aluminum is drawn in, to form
the cup in a multi-step process.
The crystallographic texture information is known by texture measurements of the aluminum alloy, which will be later on  necessary for the calculation as input for the crystal orientations.
With the simulations, the earing profile (non-uniform cup height
after deep drawing
) is computed and compared to experimental data.
The two step deep drawing in the beverage can manufacturing process is simulated within the framework of the Finite Element Method with a two scale, strongly coupled crystal plasticity material model.
The numerical results show that the crystal plasticity model can predict the earing profile qualitatively. For an improvement of the cup height at 0° to rolling direction, a non-Taylor type model will be considered.