Numerical simulation and defect prediction of forming process for aluminum alloy sheets considering the effect of both anisotropy and lode parameter

Traditional GTN meso-damage model, neglecting the effect of anisotropy or shearing on the evolution of microvoid, leads to the lower predictive capabilities of forming defects for aluminum alloy sheets. In this paper, a modified constitutive model of aluminum alloy sheet considering the effect of both anisotropy and shearing is proposed, and the corresponding model parameters are calibrated by inverse finite element method and uniaxial tensile test of the smooth strip sheet without hole. Then, the constitutive equation of the modified model is compiled into a VUMAT subroutine using backward Euler integration algorithm and FORTRAN language to perform subsequent numerical simulation in ABAQUS/Explicit, the validity of the proposed shearcorrected GTN model is also verified through the uniaxial tensile experiment of the strip sheet with a hole in the middle. Finally, finite element (FE) model of the mould-sheet coupling system is developed based on the modified GTN model, and the influence of punching speed, blank holder force, friction coefficient and dwell time on the forming performance of AA5052 aluminum alloy sheet is investigated. The results show that ductile fracture of aluminum alloy sheet is most prone to exist on the upper fillet of part.