Cup drawing predictions for a 6016-T4 aluminum alloy

Abstract This study investigates the interplay between process and computation parameters affecting the accuracy of finite element analysis (FEA) results for cup manufacturing. By revisiting the Esaform-2021 benchmark, this research aims to elucidate the impact of process parameters on FEA accuracy and recommend strategies for enhancing cup drawing fidelity. By conducting a parametric study focusing on the force–displacement behavior of a 6016-T4 alloy cup drawing process, an “optimized” force–displacement curve was obtained, demonstrating improved agreement with reference results. Die clearance, friction coefficient, time step size, and termination time are used in parametric finite element study. Key findings from the parametric study can be concluded that die clearance significantly affects punch force; a die clearance of 1.4 mm yielded the best match with experimental results, attributed to reduced blank-stuck phenomenon compared to smaller clearances. The friction coefficient showed a direct impact; a friction coefficient of μ = 0.1 accurately replicated the experimental peak force, highlighting the sensitivity of force predictions to friction parameters. Time step size and termination time demonstrated minimal influence on FEA results, suggesting prioritization of parameters accelerating solution time. Finally, the relationships between process and FEA computation parameters and predictions were revealed for more realistic cup drawing process prediction accuracy.