Mesh refinement study and experimental validation for stretch bending of sheet metals

For sheet metal parts with small radii and large bending angles, the sheet metal forming simulation reaches their application limits. Alternatives are complex shell formulations and volume elements. For volume elements, the necessary number of elements over the thickness is important. Valid values are not available depending on discrete radii. Therefore in this work, a convergence study is performed using the example of an angular stretch bend test with a radius to thickness ratio of 1. For various states of mesh refinement, simulations are performed, various results are presented, analysed and discussed with regard to convergence behaviour to the necessary number of elements in thickness direction. Recommendations for suitable validation variables are derived. Based on the refinement study, a simulation model for an experimental validation is developed. The experiments are carried out in a sheet metal forming machine. Experimental angular stretch bend test with a punch radius of 1 mm are performed until failure and the strain distribution on the top side of the sheet is measured. Finally, simulation and experiments are compared based on the surface strain.