Numerical simulation of profile and formability during multi-stage deep drawing and ironing for Al3003-H14 square lithium battery shell

This study aims to predict the thickness variation of Al3003-H14 square lithium battery shells during multi-stage deep drawing and ironing processes. A modified material model, MAT122_3R_3D_CL_user, was developed by coupling the Hill'48 yield function and Cockcroft & Latham ductile damage criterion through secondary development in LS-DYNA. Anisotropic parameters for MAT122_3R_3D were determined using Lankford coefficients ( r 0 , r 45 , r 90 ) obtained from uniaxial tensile tests. Numerical simulations with 3D solid elements accurately captured thickness changes and failure positions, which aligned well with experimental results. The causes of thickness deviations, including simplified assumptions for anisotropic coefficients and constant friction condition, were analysed. The proposed model enables optimization of process parameters to prevent excessive thinning or fracture during forming.