Numerical Simulation of Damage on Warm Deep Drawing of Al 6061-T6 Aluminium Alloy

This work focuses on the numerical simulation of warm deep drawing operation of car sump oil made with Al 6061-T6 aluminum alloy for the purpose of process optimization. The thermo visco-plastic behavior with damage effect of the material is described by the Johnson-Cook (JC) model. The JC model parameters for the Al 6061-T6 Aluminum alloy were exploited. Numerical simulation of the deep drawing operation was performed with the use of the ABAQUS FE software thanks to the dynamic Explicit Temperature-Displacement algorithm. The design of the different tools is obtained on the basis of the geometry of the finished product. Designing of punch, die and blank holder is performed using CATIA 3D CAD software. The warm forming method involves the heating of the blank holder and the die to a certain temperature, whereas, the punch is kept at room temperature. In this study, predefined temperatures of the die and blank holder and punch speed will be investigated among other stamping parameters. The computed damage evolution curves for a given set of the process parameters are retrieved at the end of the simulation to determine suitable forming conditions. It can be noted that the slower the damage evolution achieved within the blank, the more appropriate the process parameters. Thus, by increasing strain rate, main cracks change location. The dynamic explicit temperature-displacement algorithm available in Abaqus is used to solve the equilibrium problem with temperature effect in order to investigate the appropriateness of the process parameters on the basis of the computed damage-displacement curves