Prediction and assessment of skid line formation during deep drawing of sheet metal components by using FEM simulation

Abstract

Abstract The subjective perception of the quality of sheet metal components mainly depends on geometric characteristics and surface structures. In this context, particular attention must be paid to avoiding surface defects such as skid lines during the sheet metal forming process for components with high surface quality requirements (e.g. outer skin passenger car panels). In principal, FEM simulation can provide an effective tool for predicting such surface defects. However, the numerical modelling approaches available today do not yet allow an adequate basis for assessing their quality relevance in production, which especially applies to skid lines. In a previously published study, new skid line criteria were developed in this regard, considering unbending strain, thinning and major strain. Using a simple steel sheet part (DC06) as reference, the study showed that these criteria allow the quality relevance of skid lines to be predicted relatively accurately. This paper focuses on the validation of the proposed skid line criteria and their applicability to the materials DC06 and AA6016. Furthermore, the numerical studies presented show that one of the novel skid line criteria, which considers unbending strain and thinning, is able to accurately locate and predict the quality relevance of skid lines even for complex shaped parts.