Study on the Influence of Isotropic Simplification in Flexible Multi-Point Stretch-Bending Forming with Roller Dies

For the flexible multi-point stretch-bending forming process, which involves complex forming procedures, finite element (FE) modeling can significantly reduce trial-and-error costs and provide a convenient means for determining process parameters in actual production. During the creation of FE models, simplifying the material model is crucial: insufficient simplification greatly increases computation time, while excessive simplification reduces model accuracy. This study establishes user material subroutines in the FE simulation software Abaqus to introduce anisotropic yield models, specifically Hill’s 48 and Yld2004-18p models. Multi-point stretch-bending experiments were repeated and compared with simulations using the traditional isotropic Von Mises yield model to analyze the impact of isotropic simplification on the accuracy of forming results. The applicability of isotropic simplification under different degrees of deformation is investigated, and the fundamental causes of errors are analyzed. Ultimately, the error response of the material simplified model is obtained. This provides an error reduction scheme for subsequent research using the isotropic simplified model.