Development of forming limit diagrams for motorcycle fuel tank made from AA5754-O under deep drawing

Abstract

The research studied forming limit curves (FLC) for aluminum alloy 5754-O (AA5754-O) and modified them using two methods. These methods aimed to create FLCs for application in describing the forming behavior of sheet metal material through a deep drawing process simulation in the PAM-STAMP program. The methods are as follows: The Nakajima test combined with a new method, a novel process for grid creation on the specimen: laser marking combined with elastic paints. A mathematical material model using the fracture model along with the yield criteria: YLD2000-2D and hardening law: Swift-Voce. The Keeler-Brazier modified equation was chosen as the fracture model for this research because it is an effective equation for creating FLCs for steel materials and has not yet been applied to aluminum materials. Furthermore, no one has previously used the Keeler-Brazier modified equation in conjunction with YLD2000-2D and the yield criterion Swift-Voce hardening law. In summary, the FLC generated from YLD2000-2D, Swift-Voce hardening law, and Keeler-Brazier modified equations can predict the location of damage occurrence on the motorcycle fuel tank, which occurs due to the deep drawing process, using finite element simulation accurately. This closely resembles the actual forming process in the industry.