Some phenomenological and computational aspects of sheet metal blanking simulation

In this paper, we present a comprehensive experimental and numerical study of the sheet metal blanking process. Various blanking tests involving different materials and geometry are investigated and the numerical results are compared with experimental data. For the numerical aspects of this study, the main topics discussed are sheet metal constitutive model, the numerical integration algorithm and mesh adaptivity. Taking into account the complexity of the blanking process, we chose an explicit finite element code to overcome the convergence problems. Our numerical model is thus based on a dynamic explicit scheme associated with the ALE formulation for mesh adaptivity. Since the choice of the sheet metal constitutive model is important to achieve the product shape prediction and the burr height estimation, we compare the Pamdtl-Reuss plasticity model with Gurson-Tvergaard-Needleman coupled plasticity-damage model. The comparisons between numerical results and measurements show that the maximum punch force is strongly related to the plastic flow but that the burr height estimation requires damage modelling. In addition, Gurson's modified model greatly improves the punch force prediction. (C) 2002 Elsevier Science B.V. All rights reserved.