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<p>NUMISHEET 2011The NUMISHEET 2011 Benchmark Study of the 8th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes Seoul, Korea 2126 August 2011 PART C BENCHMARK PROBLEMS AND RESULTS Editors Hoon Huh KAIST Kwansoo Chung Seoul National University Soo Sik Han Kumoh National Institute of Technology Whan Jin Chung Seoul National University of Science and TechnologyBenchmark Organizers Alcoa Kangwon National University POSCO KAIST Daegu University Seoul National University OrganizationKAIST SNUKorea Advanced Institute of Science and Technology Seoul National University The Korean Society for Technology of Plasticity NUMISHEET 2011 The NUMISHEET 2011 Benchmark Study of the 8th International Conference and Workshop on Numerical Simulation of 3D Sheet Metal Forming Processes August 2126, 2011, Seoul, Korea PART C BENCHMARK PROBLEMS AND RESULTS Editors Hoon Huh KAIST Kwansoo Chung Seoul National University Soo Sik Han Kumoh National Institute of Technology Wan Jin Chung Seoul National University of Science and Technology Benchmark Organizers Alcoa Kangwon National University POSCO KAIST Daegu University Seoul National University Organization KAIST SNU Korea Advanced Institute of Science and Technology Seoul National University The Korean Society for Technology of Plasticity EDITORS Hoon Huh Korea Advanced Institute of Science and Technology 291 Daehak-ro, Yuseong-gu, Daejeon 305-701 Korea hhuh@kaist.ac.kr Kwansoo Chung Seoul National University Daehak-dong, Gwanak-gu, Seoul 151-744 Korea kchung@snu.ac.kr Soo Sik Han Kumoh National Institute of Technology Sanho-ro 77, Gumi, Gyeongbuk 730-701 Korea sshan@kumoh.ac.kr Wan Jin Chung Seoul National University of Science and Technology 172 Gongreung 2-dong, Nowon-gu, Seoul 139-743 Korea wjchung@snut.ac.kr KAIST PRESS Korea Advanced Institute of Science and Technology 291 Daehak-ro, Yuseong-gu, Daejeon 305-701 Korea www.kaistpress.com Printed in Korea ISBN 9788989453482 - III TABLE OF CONTENTS PREFACE V ACKNOWLEDGEMENT VI ORGANIZATION OF NUMISHEET 2011 VII BENCHMARKS GENERAL SPECIFICATIONS 3 LIST OF PARTICIPANTS 4 BM1 Earing Evolution during Drawing and Ironing Processes Benchmark Description 11 General Information of Participants and Solution Methods 14 Summary of Simulation Conditions and Methods 36 List of figures 38 Results of AA5052 39 Results of AKDQ 44 BM2 Simulation of the Cross-shaped Cup Deep-drawing Process Benchmark Description 51 General Information of Participants and Solution Methods 56 Summary of Simulation Conditions and Methods 72 List of Figures 73 List of Tables 79 Results of AZ31B ( = 0.05) 80 Results of AZ31B ( = 0.10) 104 - IV BM3 CAE-based Optimization of Stamping Processes for a Front Side Member Benchmark Description 131 General Information of Participants and Solution Methods 139 Summary of Simulation Conditions and Methods 158 List of Figures 159 Results of DP590 160 BM4 Pre-strain Effect on Spring-back of 2-D Draw Bending Benchmark Description 173 General Information of Participants and Solution Methods 178 Summary of Simulation Conditions and Methods 207 List of Figures 209 Results of DP780 211 APPENDIX A BM1 (AA5042, AKDQ Steel) 229 APPENDIX B BM2 (AZ31B) 235 APPENDIX C BM3 (DP590) 237 APPENDIX D BM4 (DP780) 239 PARTICIPANTS FOR BENCHMARK 243 - V - PREFACE In the era of ever more rapid development of science and technology, the numerical technology might be one of the most significant advancement, contributing in all engineering areas. Especially, in the field of sheet metal forming, the progress of numerical methods during the last half a century was so immense, changing all academic and industrial practices in this field. Amid such numerical technology advancement, the NUMISHEET conference has been established as a triennial world-class forum ever since 1989, making major contribution in the field of the numerical modeling of sheet metal forming processes: Colorado (USA, 1989), Zurich (Switzerland, 1991), Isehara (Japan, 1993), Dearborn (USA, 1996), Besancon (France, 1999), Jeju Island (Korea, 2002), Detroit (USA, 2005), Interlaken (Switzerland, 2008). Now, its 8th conference (counted from the conference in Zurich1), NUMISHEET 2011, is held in Seoul, Korea. It is our great pleasure to invite you all, scientists and engineers including software developers and industrial users as well as students, to participate in the event to promote exchanges of valuable experiences and new ideas on numerical methods, material modeling as well as forming technologies. Following the conference tradition, the conference features technical sessions along with keynote lectures, benchmark sessions to compare numerical predictions with experiments and also technical tours. In the early stage of the advancement of numerical methods, major technical topics were focused on numerical technologies including various algorithms associated with integration schemes, element types and contact problems. However, as these issues settled, new topics emerged in the area of material modeling including new characterization methods and constitutive modeling as well as new forming technologies to meet challenges associated with newly emerging light or high strength sheets, which are demanded as an element of the green technology. To address such new technical demand, technical sessions consist of Constitutive modeling, Materials testing, Crashworthiness, Crystal plasticity/multi-scaling, Finite element techniques, Fracture/damage, High temperature forming, Hydroforming, Process modeling/optimization, Process design/rigid packaging and Spring-back. The benchmark topics cover forming of aluminum and magnesium alloys as well as advanced high strength steels: Earing evolution during drawing and ironing processes (AA 5042 aluminum/AKDQ steel), Simulation of the cross-shaped cup deep-drawing process (AZ31B magnesium), CAE-based optimization of stamping processes for a front side member (DP590 steel), Pre-strained effect on spring-back of 2-D draw bending (DP780 steel). Also, note that a new session is set aside for the first time solely for young (graduate school) researchers to promote their own interactions without involvement of their seniors. As for the technical tours, visiting Hyundai Steel (Dang-Jin) Plant and GM Korea (Bu-Pyung) Plant is arranged. We deeply appreciate your participation in the NUMISHEET 2011 conference, which is most important for the success of the conference. Seoul, June 23, 2011 NUMISHEET2011 Organizing Committee Kwansoo Chung, Hoon Huh, Frederic Barlat, Young Hoon Moon, Heung Nam Han 1The first one in Colorado was a meeting. Details are referred to the article The early history of the NUMISHEET benchmarks and international conferences written by Wagoner and Hora in the current conference proceedings. - VI - ACKNOWLEDGEMENT The utmost appreciation for the success of the NUMISHEET2011 conference goes to all scientists and engineers from academia and industry, who participated in The NUMISHEET conference sharing their valuable experiences and ideas with/without their technical presentations and benchmark solutions. We also greatly appreciate the devoted services of all committee members, plenary lecturers and session organizers/chairpersons, who are listed in the program booklet and proceedings. The success of the conference was also immensely indebted to following contributors, who supported the conference through generous finances and devoted services, but not explicitly recognized in any printed form elsewhere. First, we would like to gratefully appreciate the financial support of our sponsors: POSCO and Hyundai Steel as Gold Sponsors, TATA Steel, AutoForm Engineering GmbH, Quantech ATZ and JSOL Corporation as Silver Sponsors, BK21-Materials Education and Research Division, KIMS, KITECH, DMI and Sungwoo Hi-Tech as Bronze Sponsors. Financial supports from RIAM (Research Institute of Advanced Materials at Seoul National University), Seoul Tourism Organization, KOFST (the Korean Federation of Science and Technology Societies Grant), MKE (the Ministry of Knowledge Economy Grant, B551179-11-02-00) and NRF (the National Research Foundation of Korea Grants funded by the Korean Government, 2010-220-D00037 and 2011-0020493) are also deeply appreciated. We also would like to thank Hyundai Steel and GM Korea for providing technical tours. As for the NUMISHEET 2011 Benchmark session, its success owed a great deal to contributors who devoted their services in various ways behind the scenes, which are also gratefully appreciated. For BM1, Dr. Keun-Hwan Kim and Mr. Jae Heon Park (POSCO) supplied steel samples, while Mr. John Brem (who retired now) and Mr. Edward Llewellyn at Alcoa Technical Center conducted intensive materials characterization. Mr. Robert E. Dick at Alcoa Technical Center also performed the standard experiment. For BM2, Dr. Seok Moo Hong (Samsung Electronics) supported developing the cross-shaped cup deep-drawing die and Mr. Hong-Jeon Baek (AUSTEM) supplied the AZ31 samples, while Mr. Myung Geun Lee (Kangwon National University) performed the experimental work and Mr. Taejoon Park (Seoul National University) performed the numerical calibration work. For BM3, Dr. Kanghwan Ahn (POSCO) supplied the DP590 samples, while Prof. F. Barlat, Prof. Myoung-Gyu Lee (POSTECH) and Dr. Gihyun Bae (KAIST) performed the material characterization and Mr. Hyunjun Choi (Daegu University) performed the experimental work. As for BM4, Mr. Gi-Dong Lee (Hwashin) supplied DP780 samples, while Dr. Kanghwan Ahn (POSCO), Mr. Yuki Ogihara (TUAT) and Dr. Xu Le (POSTECH) performed the experimental work. A draft of benchmark results was prepared by Dr. Gihyun Bae (KAIST) whose effort and devotion has made the NUMISHEET 2011 Benchmark volume well arranged. We are also so grateful to Prof. Jeong-Whan Yoon (Swinburne University) and Prof. Jian Cao (Northwestern University) for timely advice and guidance. Also, the organization committee gratefully acknowledges the services provided by the members of the Materials Mechanics Laboratory (SNU), Computational Solid Mechanics and Design Laboratory (KAIST), Materials Mechanics Laboratory (GIFT), Advanced Materials Processing Technology Laboratory (Pusan University), Micro Mechanics and Material Processing Design Laboratory (SNU). Special thanks are due to Mr. Dong Yoon Seok (SNU), who took care of errands and chores as well as correspondence. NUMISHEET2011 Organizing Committee Kwansoo Chung, Hoon Huh, Heung Nam Han, Young Hoon Moon, Frederic Barlat - VII - ORGANIZATION OF NUMISHEET 2011 CHAIRMAN Chung, Kwansoo (Seoul National University, Korea) COCHAIRMAN Huh, Hoon (Korean Advanced Institute of Science and Technology, Korea) Barlat, Frdric (Pohang University of Science and Technology, Korea) Moon, Young Hoon (Pusan National University, Korea) Han, Heung Nam (Seoul National University, Korea) STEERING COMMITTEE Brunet, M. (France) Gelin, J. C. (France) Hora, P. (Switzerland) Lee, J. K. (USA) Nakamachi, E. (Japan) Oh, Soo Ik (Korea) Pourboghrat, F. (USA) Stoughton, T. B. (USA) Wagoner, R. H. (USA) Yang, Dong-Yol (Korea) INTERNATIONAL SCIENTIFIC COMMITTEE Alexandrov, S. (Russia) Aretz, H. (Germany) Balan, T. (France) Banabic, D. (Romania) Batoz, J. L. (France) Bouvier, S. (France) Cao, J. (USA) Carsely, J. (USA) Cazacu, O. (USA) Chastel, Y. (France) Chen, J. (China) Chenot, J. L. (France) Choi, Tae Hoon (Korea) Dick, R. E. (USA) Ghosh, S. (USA) Gracio, J. J. (Portugal) Habraken, A. M. (Belgium) Halder, A. (India) Han, Chung-Souk (USA) Hartley, P. (UK) Huetink, J. (Netherlands) Iadicola, M. (USA) Im, Yong Bin (Korea) Kessler, L. (Germany) Keum, Young-Tak (Korea) Khan, A. S. (USA) Kim, Chongmin (Korea) Kim, Sung-Joon (Korea) Kim, Young-suk (Korea) Korhonen, A. S. (Finland) Kuroda, M. (Japan) Kuwabara, T. (Japan) Li, X. X. (China) Lim, Jong Dae (Korea) Martins, P. (Portugal) Massoni, E. (France) Mattiasson, K. (Sweden) Meinders, T. (Netherlands) Merklein, M. (Germany) Narasimhan, K. (India) Ofenheimer, A. (Austria) Park, Sung-Ho (Korea) Roll, K. (Germany) Rousselier, G. (France) Ruan, X. Y. (China) Smith, L. M. (USA) Takahashi, S. (Japan) Tekkaya, A. E. (Turkey) Tzou, G. Y. (Taiwan) Van Tyne, C. J. (USA) Vegter, H. (Netherlands) Worswick, M. (Canada) Wu, P. (Canada) Yoon, Jeong-Whan (Australia) Yoshida, F. (Japan) ADVISORY COMMITTEE Bhattacharjee, D. (India) Cho, Won-Suk (Korea) Ham, Youngki (Korea) Kwon, Oh Joon (Korea) Moon, Man-Been (Korea) Park, Jong Jin (Korea) Yoon, Jeong-Whan (Australia) - VIII - BENCHMARK COMMITTEE Huh, Hoon (Chairman, Korea Advanced Institute of Science and Technology, Korea) Chung, Wan Jin (Co-Chairman, Seoul National University of Technology, Korea) Han, Soo Sik (Co-Chairman, Kumoh National Institute of Technology, Korea) Suh, Yeong Sung (Co-Chairman, Hannam University) BM1 Yoon, Jeong-Whan (Chairman, Swinburne University, Australia) Dick, Robert E. (Co-Chairman, ALCOA, USA) BM2 Kim, Heon Young (Chairman, Kangwon National University, Korea) Kim, Hyung Jong (Co-Chairman, Kangwon National University, Korea) BM3 Kim, Se-Ho (Chairman, Daegu University, Korea) Kang, Yeon Sik (Co-Chairman, POSCO, Korea) Kim, Dongjin (Co-Chairman, POSCO, Korea) BM4 Chung, Kwansoo (Chairman, Seoul National University, Korea) Kuwabara, Toshihiko (Co-Chairman, Tokyo University of Agriculture and Technology, Japan) Ahn, Deok Chan (Korea) Bae, Gihyun (Korea) Choi, Tae Hoon (Korea) Hong, Seung Hyun (Korea) Kim, Daeyong (Korea) Kim, Heung Kyu (Korea) Kim, Jong Bong (Korea) Kim, Tae Joon (Korea) Lee, Hyoungjin (Korea) Lee, Moon Yong (Korea) Lee, Myoung-Gyu (Korea) Moon, Myungsoo (Korea) Park, Jae Heon (Korea) Park, Taejoon (Korea) Verma, Rahul K. (India) Yoo, Dong Jin (Korea) PUBLICATIONS COMMITTEE Barlat, Frdric (Chairman, POSTECH, Korea) Han, Heung Nam (Korea) Choi, Shi-Hoon (Korea) Lee, Myoung-Gyu (Korea) Lee, Wonoh (Korea) Kim Ji Hoon (Korea) PROGRAM COMMITTEE Moon, Young Hoon (Chairman, Pusan National University, Korea) Han, Heung Nam (Co-Chairman, Seoul N...</p>