Use of Non-Quadratic Yield Surfaces in Design of Optimal Deep-Draw Blank Geometry

Planar anisotropy in the deep-drawing of sheet can lead to the formation of ears in cylindrical cups and to undesirable metal flow in the blankholder in the general case. For design analysis purposes in non-linear finite-element codes, this anisotropy is characterized by the use of an appropriate yield surface which is then implemented into codes such as DYNA3D. The quadratic Hill yield surface offers a relatively straightforward implementation and can be formulated to be invariant to the coordinate system. Non-quadratic yield surfaces can provide more realistic strength or strain increment ratios, but they may not provide invariance and thus demand certain approximations. Forms due to Hosford and Barlat et al. have been shown to more accurately address the earing phenomenon. In this work, use is made of these non-quadratic yield surfaces in order to determine the optimal blank shape for cups and other shapes using ferrous and other metal blank materials with planar anisotropy. The analyses are compared to previous experimental studies on non-uniform blank motion due to anisotropy and asymmetric geometry.