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Technical Paper

A Simplified 2D Model for Predicting Corner Failure in a Square Part

1999-03-01
1999-01-1317
The traditional practice of setting up a new forming operation relies on years of experience and expensive die try-outs to gather the information for die design. Today's complete modeling of a 3D sheet metal forming can provide accurate information but is usually too time consuming. Currently, the time and cost effective method used in industries is to model the straight side of a 3D part as a plane strain problem and the corner section as an axisymmetric problem. Unfortunately, the axisymmetric solution often over-predicts the severity of the deformation at the corner and leads to a very conservative design. In an effort to improve the predictability of the simplified 2D model, an axisymmetric model with a center offset is proposed in this study. The proposed center offset is found to be a function of the center strains, failure height, and process parameters, which include tooling geometry, material properties, friction coefficient, and restraining force.
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