Application of Erichsen test to sheet metal materials and simulation using finite element method

In this thesis study, a study was carried out on the verification of the Erichsen test results performed on 1050 series aluminum, 304 steel, galvanized steel and S235JR steel metals with a numerical analysis study based on the finite element method. Choosing the appropriate material for the process is of critical importance in order to bring metal materials into the designed shapes by passing them through various processes. Formability capacity is a feature that should be evaluated for metal materials in creating the desired design permanently on sheet metals by using the plastic deformation regions of metal materials. In this study, the Erichsen Test defined by the EN ISO 20482:13 standard developed to measure the formability values of metal sheets is 1mm. It was carried out on 4 different metal materials and 3 different test results were obtained from each sample. As a result of the experiments carried out, the average Erichsen test result measured for 1050 aluminum material samples was 8,3 mm was realized as. In the test results carried out for galvanized steel, the average Erichsen test result is 11,5 mm was realized as. The average result of the Erichsen test conducted for the S235JR material sample is 9,2 mm was realized as. As a result of the test carried out for 304 steel, according to the results of two Erichsen tests, 12,6 mm and 12,7 mm. No usable Erichsen test results were obtained for 304 steel from the test device, which could not continue deformation because no cracks occurred on the material at two value points and the punch displacement of the test device reached its highest value. In this thesis study, the Erichsen test was modeled through the analysis program with the support of an analysis program using the finite element method-based explicity solution method. The results obtained were compared with the results obtained from the Erichsen experiment. The properties determined by the tensile test results found in the literature for the relevant materials were defined as material properties input in the analysis program. The thesis predicts that the test results of a non-linear process involving a high amount of deformation, such as the Erichsen experiment, can be calculated using the basic material properties obtained from tensile tests through an analysis program. In the analysis study of the results of the Erichsen test, it was aimed to reach the conclusion based on the assumption that cracking will occur at the critical yield stress point of the material and that the deformation at the point where the critical yield stress occurs can confirm the result of the Erichsen test. As a result of the analysis study, the average Erichsen test result was 8,3 mm. The estimated crack formation value of 1050 aluminum material is 9,2 mm with a deviation of % 10,8 has been found. The Erichsen test result for S235JR is 9,2 mm. As a result of the analysis, a result of 9,8 was reached with a deviation of % 6,5. 11,5 mm reading in Erichsen test for galvanized steel. As a result of the analysis, the value is 12,1 mm with a deviation of % 5,2. It was calculated as . The results compared with this method showed the potential of this method for processes in terms of cost by proving that the possible results of the tests needed in the material selection process in the design process can be calculated with computer-aided analysis programs by using the finite element method.