eISSN: 2289-8107 Special Issue iDECON 2016 Infuences of Draw Forming Process on the Crash Analysis of a Circular Cup 547 INFLUENCES OF DRAW FORMING PROCESS ON THE CRASH ANALYSIS OF A CIRCULAR CUP R.M. Amman 1 , M.F. Halim 2 , D. Sivakumar 1 , I. Abu-Shah 2 , S.N. Sulaiman 2 , H. Samekto 1 and S. Subramonian 3 1 Faculty of Mechanical Engineering, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia. 2 Faculty of Technology Engineering, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka. 3 Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka. Corresponding Author’s Email: 1 sivakumard@utem.edu.my Article History: Received 6 August 2017; Revised 19 October 2017; Accepted 15 December 2017 ABSTRACT: The change of a structural part that occurred after forming process can affect crash response. Current industrial practice only utilizes the geometry in crash analysis. This study investigates the effect of forming histories of a circular cup formed by draw forming process in the crash simulation. Crash analysis at an initial velocity of 50km/h was performed using the explicit finite element code Radioss. The Johnson-Cook constitutive material model was used to characterize the material properties of advanced high strength steel DP600. Crash simulations are conducted in two different cases using a geometrical cup model with case 1 no forming history and case 2 all forming histories obtained from forming process. Results from this study indicate that the mechanical response of steel DP600 in a crash differ by 80.7 % for contact force and 5.87% for energy absorption when forming effects were considered. The contact force tends to increase more with displacement in case 2 compared to case 1. The non-uniform thickness and work hardening from forming process do alter significantly the crashworthiness of a structural part in the subsequent crash event. KEYWORDS: Draw forming; Circular cup; Crash analysis; Steel DP600 brought to you by CORE View metadata, citation and similar papers at core.ac.uk provided by Universiti Teknikal Malaysia Melaka: UTeM Open Journal System