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<p>This study aims to introduce and validate the wrinkling limit curves (WLCs) obtained using various methodologies, including analytical calculations, experimental techniques combined with digital image correlation, and numerical simulations. Finite element (FE) simulations based on Hill’48 anisotropic yield criterion of Yoshida buckling samples were carried out for two aluminum thin sheet grades AA5052-O and AA5052-H32 with different heat-treating routes under both rolling and transverse directions. Hereby, WLCs of both aluminum sheets were determined, and their formability regarding non-flange wrinkling was thoroughly characterized. Subsequently, the applicability of developed WLCs was evaluated through experimental and FE analysis of conical cup drawing tests, in which varying blank holder forces were incorporated to induce severe and non-flange wrinkling occurrences. The AA5052-O sheet exhibited greater tendency of severe wrinkles than the AA5052-H32 sheet, attributed to its significantly lower plastic yield stress and strain hardening rate as a result of different heat treatment processes. Moreover, the WLCs by FE simulations provided the most accurate predictions of the onset of non-flange wrinkles, whereas the analytical method obviously tended to overestimate experimental results. The WLCs for the transverse direction indicated higher forming limits than those for the rolling direction, correlating well with the material’s anisotropy. This work provides a comprehensive framework for determining the non-flange WLCs by various methods and their comparative studies on an industrial part.</p>

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Comparative wrinkle assessments for cup drawing of aluminum alloy sheets by analytical, experimental and numerical approaches

  • 期刊论文

  • 发表日期：

    2026年1月20日

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  • Sansot Panich,
  • Wasu Polpruk,
  • Vitoon Uthaisangsuk

摘要

This study aims to introduce and validate the wrinkling limit curves (WLCs) obtained using various methodologies, including analytical calculations, experimental techniques combined with digital image correlation, and numerical simulations. Finite element (FE) simulations based on Hill’48 anisotropic yield criterion of Yoshida buckling samples were carried out for two aluminum thin sheet grades AA5052-O and AA5052-H32 with different heat-treating routes under both rolling and transverse directions. Hereby, WLCs of both aluminum sheets were determined, and their formability regarding non-flange wrinkling was thoroughly characterized. Subsequently, the applicability of developed WLCs was evaluated through experimental and FE analysis of conical cup drawing tests, in which varying blank holder forces were incorporated to induce severe and non-flange wrinkling occurrences. The AA5052-O sheet exhibited greater tendency of severe wrinkles than the AA5052-H32 sheet, attributed to its significantly lower plastic yield stress and strain hardening rate as a result of different heat treatment processes. Moreover, the WLCs by FE simulations provided the most accurate predictions of the onset of non-flange wrinkles, whereas the analytical method obviously tended to overestimate experimental results. The WLCs for the transverse direction indicated higher forming limits than those for the rolling direction, correlating well with the material’s anisotropy. This work provides a comprehensive framework for determining the non-flange WLCs by various methods and their comparative studies on an industrial part.