Simulation of ultra-thin sheet metal forming using phenomenological and crystal plasticity models

Micro-forming of ultra-thin sheet metals raises numerous challenges. In this investigation, the predictions of state-of-the-art crystal plasticity (CP) and phenomenological models are compared in the framework of industrial bending-dominated forming processes. Sheet copper alloys 0.1mm-thick are considered, with more than 20 grains through the thickness. Consequently, both model approaches are valid on theoretical ground. The phenomenological models’ performance was conditioned by the experimental database used for parameter identification. The CP approach was more robust with respect to parameter identification, while allowing for a less flexible description of kinematic hardening, at the cost of finer mesh and specific grain-meshing strategies. The conditions for accurate springback predictions with CP-based models are investigated, in an attempt to bring these models at the robustness level required for industrial application