Sheet metal anisotropy and optimal non-round blank design in high-speed multi-step forming of AA3104-H19 aluminium alloy can body

  • Wencheng Liu
  • Bernard K Chen


A new anisotropic yield function which accurately describes the complex anisotropy of aluminium alloy sheet metal is proposed in this paper. A non-linear least square method is used to determine the coefficients of this yield function based on the experimental results. By employing the back-Euler stress integration algorithm, this anisotropic constitutive model has been successfully implemented in commercial FEM software ABAQUS via user material subroutine UMAT to predict earing profile of AA3104-H19 deep-drawn and redrawn cups. Good agreement was found in the predicted earing profiles and those obtained in experimental deep-drawn and redrawn cups. The FE model was used in an iteration optimisation process to determine the optimal shape of non-round blanks to obtain the ear-free deep-redrawn cups, and non-round tooling was designed accordingly. Results showed the height of the ears is significantly reduced in the cup formed using this non-round blank compared with that of a conventional round blank which is important for smooth running of high-speed multi-step forming of aluminium can body.


Yield function Non-round blank Anisotropy Ear-free 


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The authors are grateful to Mr Mike Shirran for the technical support for this work.

Compliance with ethical standards

Conflict of interest

The authors declare that they have no conflict of interest.


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© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  1. 1.Department of Mechanical and Aerospace EngineeringMonash UniversityMelbourneAustralia

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