Modeling the strain localization of shell elements subjected to combined stretch-bend loads: Application on automotive sheet metal stamping simulations

This study presents a modeling approach for predicting strain localization during sheet metal stamping processes focused on automotive engineering applications. The so-called stretching-to-bending ratio, rho, is proposed to characterize the loading conditions acting on an element during stamping processes. Then, localized strain or necking strain is suggested to be a function of rho. Different stretch-bending tests with different tool radii, i.e., R3, R6, R10, and R50 are conducted for two automotive sheet metals, DP800 and AA6010, to identify their forming limits under combined stretch-bend loads. The calibrated necking limit curve of the AA6016 sheet is then employed in AutoForm R10 software to predict the necking and failure of a stamped panel. Agreement with the experimental observation of failure positions of the panel validates the usefulness of the proposed modeling approach in practice.