A benchmark study for different numerical parameters and their impact on the calculated strain levels for a model part door outer

To increase the accuracy of finite element simulations in daily practice the local German and Austrian Deep Drawing Research Groups of IDDRG founded a special Working Group in year 2000. The main objective of this group was the continuously ongoing study and discussion of numerical / material effects in simulation jobs and to work out possible solutions. As a first theme of this group the intensive study of small die radii and the possibility of detecting material failure in these critical forming positions was selected. The part itself is a fictional body panel outside in which the original door handle of the VW Golf A4 has been constructed, a typical position of possible material necking or rupture in the press shop. All conditions to do a successful simulation have been taken care of in advance, material data, boundary conditions, friction, FLC and others where determined for the two materials in investigation — a mild steel and a dual phase steel HXT500X. The results of the experiments have been used to design the descriptions of two different benchmark runs for the simulation. The simulations with different programs as well as with different parameters showed on one hand negligible and on the other hand parameters with strong impact on the result — thereby having a different impact on a possible material failure prediction.