Dimensioning of sheet bending process trough ductile damage

Resumo

This work seeks to dimension the sheet metal bending process through the control of ductile damage.
For this, the material parameters of a 6101-T6 aluminum alloy are used. The process is simulated on a commercial
finite element tool as an elastoplastic problem with ductile damage. Parameters such as sheet thickness and
geometry of forming tools are evaluated. Thus, possible problems associated with the process are analyzed, such
as cracks in the bending regions, fractures and deformations. Three sheet thicknesses are evaluated, more
specifically 1, 2 and 3 mm. For the 3 mm sheet, a new geometry of the forming tool was proposed in order to
smooth the entire process. Three parts were modeled for analysis: two parts for forming the sheet, called tools "A"
and "B", and the sheet. Tool “A” works like a punch, tool “B” works like a mold. The problem was modeled
considering plane strain state. The tools used for the sheet bending process are modeled as rigid bodies, whereas
the sheet is modeled as a deformable solid.