Journal of Materials Processing Technology 183 (2007) 339–346

A new strategy to optimize variable blank holder force towards

improving the forming limits of aluminum sheet metal forming
Lin Zhong-qin, Wang Wu-rong ∗ , Chen Guan-long
School of Mechanical Engineering, Shanghai Jiaotong University, Shanghai 200030, China
Received 16 April 2006; received in revised form 10 September 2006; accepted 20 October 2006

Abstract
The lower formability of aluminum alloy sheet greatly limits its application in reducing weight of stamping parts. This paper proposes a new
strategy to optimize the variable blank holder force (BHF) and determine the drawing limit under the constant and variable BHF. The optimization
strategy is based on the analysis of BHF formability window and integrated into FEM code to obtain time and spatial optimal BHF that applies on
segmental binders. And then a stepped rectangular box of 60 mm drawing height with 10 segmental binders is adopted to validate the optimization
strategy. The constant BHF experiment and the derived trajectory of optimal BHF are verified on a multipoint variable BHF hydraulic press and
the experiment results correspond well with those of FEM optimization. This new BHF optimization strategy helps to determine time and spatial
optimal BHF profiles simultaneity in a single round of FEM simulation, which makes it an effective method.
© 2006 Elsevier B.V. All rights reserved.

Keywords: Blank holder force; Forming limits; Sheet metal forming; Aluminum alloy sheet

1. Introduction second system, they introduced a generalized thickness variable

The requirement to reduce the weight of car components as a
result of the introduction of legislation limiting emission has trig-
gered the use of new lightweight materials, such as high strength
steel sheet and aluminum alloy sheet. These materials could
reduce the weight remarkably, but lead to more severe wrinkling
or tearing than traditional low carbon steel because of their lower
formability. Different advanced forming methods were used to
increase the formability of aluminum alloy sheet, among which
warm forming [1] and variable BHF (VBHF) forming [2] were
two most effective ways.
About the application of blank holder force (BHF) towards
improving the forming limits of sheet metal parts, Doege and
Sommer [3] first examined the possibility of controlling the
blank holder force with respect to the displacement of the punch
as a means of safely avoiding the onset of either wrinkling or
tearing, as is shown in Fig. 1. Hardt and Lee [4] established the
first BHF system to maintain a constant blank holder displace-
ment to allow a limited amount of flange wrinkling. In their
∗ Corresponding author at: Mailbox#620, School of Mechanical Engineering,
SJTU, 800 Dongchuan Road, Shanghai 200240, China. Tel.: +86 21 34206785.
E-mail address: wwr 1979@163.com (W. Wu-rong).
to regulate the volume of material entering the die cavity, and the
thickness variable was used to control the BHF. Later, Hardt et
al. [5] employed a real-time closed-loop control of sheet forming
operations to determine optimal blank holder force trajectories.
Many other researchers conducted similar experiment based
study in the area of VBHF, which were reviewed by Obermeyer
and Majlessi [6].
As for the optimization strategy used for BHF optimization to
increase formability of metal sheet, Cao and Boyce [7] estimated
optimal binder force for a conical cup drawing by developing a
PI controller. Krishnan and Cao [8] adopted the auto-regressive
moving-average model (ARMA), which was inserted into the
FEM commercial code to achieve optimal BHF for a non-
circular part using segmental binders. An adaptive simulation
strategy was developed by Sheng et al. [9] to adjust the mag-
nitude of the BHF continuously during the simulation process.
Chengzhi et al. [10] and Wang and Lee [11] presented a similar
response surface methodology (RSM) to determinate the opti-
mum BHF of various locations for a rectangular box. Though
all these researchers gave effective approaches to optimizing
the variable BHF, the issue of intersection in BHF formabil-
ity window was not taken into account in their studies and no
study was carried on optimizing BHF to determine maximal
drawing limit. And vast number of time-consumed simulations

0924-0136/$ – see front matter © 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2006.10.027
340 L. Zhong-qin et al. / Journal of Materials Processing Technology 183 (2007) 339–346
Fig. 1. BHF working window [1].
required by RSM method to form response surface function
restricts its practicality and thus only use in spatial VBHF
optimization.
In this study, BHF formability window is first defined using
the similar concept of Fig. 1. Then the intersection and three
basic types of BHF formability window are discussed in depth,
based on which the new BHF control strategy is developed. The
new control strategy is then integrated into FEM code, through
which not only the optimal VBHF that will not cause wrinkling
and cracking will be obtained, but also the maximum drawing
height under VBHF will be determined. A step rectangular box
is selected to verify the strategy and the simulated result shows
the drawing height and formability of aluminum alloy sheet are
greatly increased under derived optimal BHF profiles compar-
ing with those under constant BHF. The time and spatial BHF
profiles are verified on a multi point VBHF press and the results
correspond well with FEM simulation.
The rest of this paper is organized as follows: in Section 2,
the BHF formability window will be first defined and analyzed,
based on which the new control strategy will be developed. Sec-
tion 3 will use FEM simulation integrating the BHF optimization
strategy to conduct a closed-loop forming simulation for the step
rectangular box. Optimal trajectories of the segmental are then
gained and the maximum drawing height is also determined.
The experiment verification will be conducted in Section 4 on
a multipoint variable BHF hydraulic press, the results of which
will be compared with those under constant BHFs. Section 5
states the conclusion.
2. PID control strategy for VBHF optimization
2.1. The definition and analysis of BHF formability window
The popular tool to denote the formability of sheet metal
blanks in stamping is the forming limit diagram (FLD), through
which the limits of formability in sheet metal operations are
described in terms of the major and minor strains distributing
in a grid coordinate system with the X- and Y-axes represent-
ing the minor and major strains. If there exist elements whose
strains are in the failure zone of the coordinate system, this means
the stamped part is cracked at the location where the elements
are. Using the general concept of safe and failure zone in FLD,
the BHF working window in Fig. 1 could be defined as a BHF
Fig. 2. The definition of BHF formability window.
formability window, which is shown in details in Fig. 2. The X-
and Y-axis of BHF formability window coordinate system are
referred as punch stroke and BHF force, respectively. The area
under Wrinkling BHF is the wrinkling region, which means if
BHF applying on tool at certain punch stroke is less than that of
Wrinkling BHF, the part will engender wrinkling defect. While
if the BHF is larger than the Tearing BHF at certain punch stroke,
tearing will occur in the part, thus the area beyond Tearing BHF
is denoted as tearing region. And the strip area between the
Tearing BHF and the Wrinkling BHF is the safe region, which
gives appropriate BHF range that will not cause wrinkling or
tearing. No material could be drawn infinitely, i.e., every mate-
rial has a formability limit, which means the part will undergo
cracking at certain drawing height no matter VBHF is applied
or not. Thus, unlike the BHF working window in Fig. 1, the
BHF formability window in this study has a intersecting point,
which is denoted by I in Fig. 2. This point of intersection demon-
strates the forming limit, the maximum drawing height of this
material.
With different combination of the Tearing BHF, Wrinkling
BHF and intersecting point, the BHF formability window could
have three basic types, which are shown in Fig. 3. In type (a),
the part could be formed free of wrinkling and tearing under a
constant BHF if the BHF is selected in the safe region of the
BHF formability window, which of course could be achieved
through careful experimental design. Moreover, the drawing
limit of this material is bigger than needed drawing height of
the designed part. And the constant BHF could be the BHF
expressed in dash line in Fig. 3(a). However, inappropriate con-
stant BHF will cause only single mode of failure, tearing or
wrinkling before the drawing height is reached. In type (b),
the drawing limit of this material is still bigger than needed
drawing height of the designed part, but constant BHF will
inevitably cross the region of tearing or wrinkling, so the part
could not be formed successfully under constant BHF. And the
part could only be formed under variable BHF. The drawing
limit free of wrinkling and cracking under constant BHF is
denoted by dash line in Fig. 3(b). While other constant BHFs
will cause wrinkling and/or tearing before the needed draw-
ing height is reached. In type (c), the drawing limit of this
material is smaller than needed drawing height of the designed
part. The maximum drawing height under constant or vari-
 L. Zhong-qin et al. / Journal of Materials Processing Technology 183 (2007) 339–346
Fig. 3. Three basic types of BHF formability window.
able BHF is the same, the point of intersection in Fig. 3(c).
As for geometry with known drawing height, this means even
the variable BHF is unable to form this part to the desired
drawing height. Under such situation, part geometry revision
or sheet material replacement with better formability will be the
choice. On the other hand, as for a new design with uncertain
drawing height, the point of intersection tells the possible max-
imum drawing limits under optimal variable BHF. These three
types of BHF formability windows demonstrated here will be
obtained qualitatively and verified experimentally in Sections 3
and 4.
As we know, the purpose of BHF is to clamp the blank
between the die and the blank holder piece, i.e., the binder tool.
The smaller the BHF, the more material will be drawn into die
cavity and participate in deformation, thus the less possible is
the tearing. And for those formable BHF formability windows,
type (a and b), the desired drawing height could be fulfilled by
constant or variable BHF, the Wrinkling BHF is just the smallest
BHF which should be applied on the binder to suppress the defect
of wrinkling. Moreover, this Wrinkling BHF will not intersect
with the Tearing BHF and thus will not cause the tearing before
the possible maximum drawing height is reached. That is to say,
the critical Wrinkling BHF in the formable BHF formability
window is the optimum variable BHF during the whole punch
stroke.
Therefore, the new strategy used in this study is that wrinkling
height is treated as controlling object and fracture is regarded as
monitoring index. The BHF will be adjusted by PID closed-loop
strategy to control wrinkling height under desired amplitude.
Meanwhile, fracture index is monitored under safe Wrinkling
BHF. If fracture also appears when the BHF reaches wrinkling
critical BHF, variable BHF is of no effect, which is illustrated
in Fig. 3(c).
Fig. 4. The measurement of FWH and SWH.
341
2.2. The detection criteria of wrinkling and tearing
In general, the concept of wrinkling is used to denote short-
waved out of plane deformation, where the sheet is in a state of
in-plane compression. In dynamic explicit FEM codes, such as
LS-DYNA3D, a quasi-static approach with explicit time integra-
tion is applied, thus the wrinkling develops gradually. Therefore,
wrinkling can be detected in a visual inspection of the deformed
state. In this study, such geometry detection method is adopted.
Fig. 4 demonstrates an example of deformed state of box stamp-
ing, from which both flange wrinkling and sidewall wrinkling
are detected. And the flange wrinkling height (FWH) could be
measured by the gap between binder and die, which is heaved
by the wave of flange wrinkling. As for the supported or unsup-
ported sidewall wrinkling height (SWH), it could be measured
by horizontal section line, which is cut from deformed blank.
When sidewall wrinkling emerges from the contour section, the
SWH can be measured by the distance of two lines, which are
tangent to wrinkled blank section. Based on literature [7–9], the
critical amplitude to identify the appearance of wrinkling are
115% and 105% of nominal blank sheet thickness for FWH and
SWH, respectively.
In the process of sheet metal stamping, tearing is usu-
ally caused by localized necking, a local region within which
the material is thinned too much. This localized necking has
been observed by numerous researches, of which two ways
were used popularly. One is strain detection, through which
the deformed strain is compared with formability limit curve
(FLC) of this material [7,8,10,11]. The other is part-thinning
detection, by which the tearing danger occurs if the maximum
thinning exceeds certain amplitude [9]. In this study, strain detec-
tion is adopted. When there exist one or more elements whose
strains exceed the failure limit of this material’s FLC, tearing
342 L. Zhong-qin et al. / Journal of Materials Processing Technology 183 (2007) 339–346

could be detected at the zone where the elements are. How- will be treated as the initial BHF for the next simulation time
ever, as is stated at the end of Section 2.1, tearing phenomenon step. Fig. 5 demonstrates the control logic in terms of flow
is only treated as monitoring index instead of a controlling chart.
object. The formula of FWH and SWH PID controller is as
follows:
2.3. The closed-loop PID control strategy for optimal
VBHF 
BHFi,j+1 = BHFi,j + Kp ei,j + Ki ei,j + Kd ei,j (1)
From the previous analysis of BHF formability window, the
optimal BHF is the minimum BHF that is just big enough to sup-
where: i, ith time step of forming simulation (i = 1, 2, . . ., n); j,
press the failure of wrinkling, i.e., the critical Wrinkling BHF
jth iteration of optimization (j = 1, 2, . . ., n); BHF, blank holder
in those formable BHF formability windows. Thus, the con-
force; BHFi,j , BHF after jth iteration for no. i time step of forming
trol logic for BHF adjustment used in this study is: the BHF
simulation; FWH, flange wrinkling height; SWH, sidewall wrin-
is adjusted by PID controller at each optimization time step so
kling height; FWHi,j , FWH after jth iteration for no. i time step
as that the BHF is just big enough to avoid wrinkling. Since
of forming simulation; SWHi,j , SWH after jth iteration for no.
the wrinkling could not be detected under the bigger BHF than
i time step of forming simulation; FWHsr , safe range of FWH;
optimal BHF, under such situation of no wrinkling it is impos-
SWHsr , safe range of SWH; nbst, nominal blank sheet thickness;
sible for the control logic to reach the optimal BHF. Therefore,
Kp , proportional gain of PID controller (>0, unit KN); Ki , inte-
the BHF should be adjusted to be small enough to cause the
gral gain of PID controller (>0, unit KN); Kd , differential gain
tendency of wrinkling but couldn’t be smaller than the critical
of PID controller (>0, unit KN); e, error between desired ampli-
Wrinkling BHF of BHF formability window. Hence, the BHF is
tude and current amplitude; ei,j , FWHi,j /nbst = 115% (when
regulated to maintain the amplitude of wrinkling at a safe range,
used for FWH PID controller), or SWHi,j /nbst = 105% (when
i.e., the wrinkling height under this BHF is bigger than the nom-
used for SWH PID controller); ei,j = ei1 + ei2 +. . .+ei,j ; ei,j =
inal blank sheet thickness, but never reach the critical amplitude
ei,j − ei,j−1 .
identifying wrinkling. Under such safe range, the sheet material
From Eq. (1), it can be seen, when the wrinkling height
will be drawn into the die cavity as much as possible, but never
exceeds critical amplitude, the BHF will be increased to elimi-
cause wrinkling or tearing. Meanwhile, the robustness of control
nate the deviation. When wrinkling height is smaller than lower
strategy is also increased. According to the critical amplitudes
limit of safe range, the BHF will be decreased to search the
to identify the existence of wrinkling, the safe ranges for FWH
optimal BHF, i.e., BHF that is just small enough to suppress
and SWH are 110–115% and 100–105% of nominal blank sheet
wrinkling.
thickness, respectively. These two safe ranges, however, would
The three constants, Kp, Ki and Kd, used in the FWH
be different for different parts depending on the requirement of
and SWH PID controller are determined by sensitivity anal-
part quality. As for the adjustment algorithm, this study employs
ysis of the BHF on the FWH and SWH through three FEM
PID controller.
simulations under different constant BHF. To catch the system
Typically, flange wrinkling usually occurs highest at initial
response, these three constant BHF should be relatively low
stage of stamping and sidewall wrinkling normally appears along
BHF that would inevitably cause flange wrinkling and sidewall
with flange wrinkling. Therefore, at each simulation time step,
wrinkling. Based on observation of both simulation and experi-
the control logic deals with flange wrinkling first. Once the
ments, the relatively low BHFs causing wrinkling could be 2KN
flange wrinkling is detected, the FWH PID controller will be
for aluminum alloy sheet using a binder with a dimension of
activated. Then the BHF will be adjusted by FWH PID con-
400 mm × 300 mm. If segmental binders are used, then the sum
troller, such that FWH is controlled under safe range of FWH,
of initial BHFs applying on each binder is also under 2KN. And
whose lower limit and upper limit are 110% and 115% of
the three gain constants for the PID controller are determined as
nominal blank sheet thickness. Then SWH will be calculated
follows:
under the acquired BHF that could suppress flange wrinkling.
If SWH exceeds the desired amplitude, i.e., 105% of nomi-
nal blank sheet thickness, BHF will be increased by SWH PID |BHFconstant3 − BHFconstant2 |
Kp = ,
controller, such that SWH is decreased to maintain in the safe |econstant3 − econstant2 |
range of SWH, i.e., 100–105% of nominal blank sheet thick-
|BHFconstant3 − BHFconstant2 |
ness. After both FWH and SWH are controlled under the safe Ki =   ,
ranges, tearing will be evaluated according to the forming limit econstant3 − econstant2 
curve of this material. If tearing occurs and the drawing height |BHFconstant3 − BHFconstant2 |
is smaller than the desired drawing height that means the min- Kd = (2)
|econstant3 − econstant2 |
imum BHF, which is just big enough to suppress wrinkling
also causes tearing. And this is the possible maximum drawing
limit of this geometry using current material. The optimiza- where e, e and e are calculated for flange wrinkling height
tion process will be terminated. If no tearing, then the BHF and sidewall wrinkling height, respectively, when used for FWH
is the optimal BHF for this simulation time step and this BHF and SWH PID controllers.
 L. Zhong-qin et al. / Journal of Materials Processing Technology 183 (2007) 339–346 343

Fig. 5. The flow chart of PID closed-loop control strategy for BHF optimization.

3. The Determination of VBHF using PID closed-loop

control strategy

3.1. FEM modeling

A step rectangle box is selected to conduct closed-loop form-

Fig. 6. Dimension of the step rectangle box.
ing simulation integrating the proposed optimization strategy.
Fig. 6 shows the dimension of this step rectangle box. Due to
its symmetry, only half of the box and six segmental binders are
meshed in Fig. 7.
The material of blank used in this study is aluminum alloy
sheet, 5754-0, and its mechanical property is listed into Table 1.

Table 1
Mechanical property of 5754-0
Yield strength, Ultimate strength, Young’s modulus, Possion’s Lankford coefficient Strength coefficient, Hardening
σ s (MPa) σ b (MPa) E (GPa) ratio (ν) K (MPa) coefficient (n)
r00 r45 r90

101 227 69 0.33 0.69 0.74 0.71 412.4 0.255

344 L. Zhong-qin et al. / Journal of Materials Processing Technology 183 (2007) 339–346

Fig. 7. Mesh model and segmental binders of the step rectangle box.

Fig. 9. Simulation result of the step box under constant 150KN BHF.

3.2. Constant BHF simulation

To determine the maximum drawing limit under constant

Fig. 8. The experiment design to search maximum constant BHF and drawing
limit.
The original size of blank is 390 mm × 290 mm, (note: since it is
a symmetrical model, blank in simulation is 390 mm × 145 mm).
The original sheet thickness is 1.5 mm. Belyschko-Tsay shell
element model with five integration points across the thick-
ness is used for the shell mesh of the blank. Barlat’s yield
criterion is adopted for material model. Friction coefficients
u = 0.12, 0.12 and 0.25 are adopted for binder/blank, die/blank
and punch/blank, respectively, which are normally used in the
sheet stamping FEM simulation under oily lubrication. From
the view of actual effect, the friction of six segmental binders
are altered by BHF applying on each binder during different
punch stroke, which generates different flow resistance at dif-
ferent location and punch to achieve optimal material flow and
best part quality.
BHF, the following experiment design in Fig. 8 is used. The
BHF that causes flange wrinkling (115–120% nbst) is the maxi-
mum constant BHF and the cracking height under this constant
BHF is the drawing limit. If the cracking height is smaller than
the desired drawing height, this means situation (b) in Fig. 3
occurs and only VBHF will be possible to form this part. In this
step box, the maximum of drawing limit is 47 mm under the
constant BHF 150KN and both failures of corner tearing and
flange wrinkling occur in the part of Fig. 8, which means the
constant BHF could not be increased. And the drawing height is
13 mm smaller than the desired drawing height; VBHF should
be applied to form this part using current material (Fig. 9).
3.3. Implementation of closed-loop PID control simulation
The initial BHFs applying on binders are BHF1 = 83 N,
BHF2 = 250 N, BHF3 = 166 N, BHF4 = 166 N, BHF5 = 250 N

Table 2
Kp , Ki and Kd for FWH and SWH PID controller used in step box

Constant BHF (N) FWH (%) SWH (%) FWH PID (KN) SWH PID (KN)

No. 1 No. 2 No. 3 No. 1 No. 2 No. 3 No. 1 No. 2 No. 3 Kp Ki Kd Kp Ki Kd

BHF1 83 133 183 117.9 116.8 115.5 106.3 106 105.5 3.84 10 25 10 10 25
BHF2 250 300 350 129 127.9 126.6 108.7 107 105.3 3.85 0.43 25 7.14 3.84 5
BHF3 166 216 216 140 135 129.4 112.8 111 107.3 0.89 0.34 8.33 1.35 2.17 2.63
BHF4 166 216 216 141.2 133.8 127.9 111.5 109.4 107.9 0.84 0.38 3.33 3.33 1.72 8.33
BHF5 250 300 350 127.3 122.4 120.7 114.3 111.4 109 2.94 0.87 1.56 2.08 1.25 10
BHF6 83 133 183 127.9 120.3 115.8 111.9 108.3 105.4 1.11 6.25 1.61 1.72 12.5 7.14
 L. Zhong-qin et al. / Journal of Materials Processing Technology 183 (2007) 339–346 345

Fig. 11. Forming limit curve of box under optimal BHF.

Fig. 10. Optimal variable BHF trajectories for six segmental binders.

and BHF6 = 83 N. First, three simulation under constant BHFs

are conducted to collect data for sensitivity analysis, through
which the three constant Kp , Ki and Kd will be calculated for
FWH and SWH PID controller used by each segmental binder.
The lengths of simulation for FWH and SWH measurement
are both five time steps. Table 2 lists the result of these three
simulations.
The closed-loop PID control strategy is integrated into LS-
DYNA3D, an explicit dynamic FEM code. The optimization
starts with the six initial BHF determined above, and only when
wrinkling heights are under safe range and no tearing occurs
under iterative BHFs, these BHFs will be recorded as optimal
BHF of the corresponding segmental binder for this optimiza-
tion time step. As is stated before, the initial BHF of 1KN
causes severe wrinkling at the start-up iterative time step. And Fig. 12. Multipoint variable BHF hydraulic press with tools.
all BHFs of six binders have been increased greatly to suppress
wrinkling for the first optimization time step. And the intersec-
tion situation that minimum BHF suppressing wrinkling also
causes tearing will terminate the optimization and send out the which the gradual decreasing of optimized BHF is the result
result of maximum possible drawing limit under optimal VBHF. of more material needed to be drawn to delay the onset of tear-
However, in this box case, there is no such intersection before ing. Fig. 11 shows the forming limit curve of this material and
the drawing limit reaches 60 mm and the optimal variable BHF the strain distribution of the simulated box under the optimized
trajectory of each segmental binder computed from the closed- variable BHF and there is no indication of wrinkling or tearing
loop PID controller is recorded and shown in Fig. 10, from failure.

Fig. 13. Stamped step box under constant BHF and optimal VBHF.
346 L. Zhong-qin et al. / Journal of Materials Processing Technology 183 (2007) 339–346
4. Experiment verification
4.1. Experiment equipment
In order to verify the PID control strategy proposed in this
study, a multipoint variable BHF hydraulic press is developed
and set up in auto-body manufacturing technology center of
SJTU to conduct variable BHF stamping experiment. Fig. 12
shows the press with tools of the step box. In this variable BHF
press, ten pins are driven by independent servo valves, which
are connected with a computer. The derived optimal trajecto-
ries could be input into computers as preset BHF curves, and
then the press will apply the predefined BHF on pins during
corresponding punch stroke.
4.2. Experiment result
Firstly, constant BHF 150KN forming experiments is con-
ducted for this step box. And the box shows local server
wrinkling in flange region and tearing in corner. The mea-
sure height is 45 mm, which is basically the same as the result
under simulation. Secondly, the optimal variable BHF trajecto-
ries derived from closed-loop PID control simulation are input
into the computer connected with the variable BHF pins. Only
slight wrinkling occurs at the flange of the step box, and draw-
ing limit reaches 60 mm. Fig. 13 shows the comparison of the
stamped part under constant BHF and optimal VBHF.
5. Conclusion
In this study, a new VBHF optimization strategy is developed
based on the BHF formability window and PID closed-loop
controller. The strategy is integrated into the FEM simulation
to determine optimal VBHF on segmental binders during the
whole punch stroke. Experiment on VBHF press shows the
derived VBHF trajectories increase the forming limit by 30%
for the step box comparing with constant BHF. The experiment
results correspond well with those of FEM simulation, which
verifies the effectiveness of the new strategy. Not only time and
spatial optimal BHF could be determined by the new BHF opti-
mization proposed in this study, but also the maximum drawing
height under constant and variable BHF could be determined for
different geometry, which makes it a robust method.
Acknowledgement
The support from NSFC through Nature National Young Sci-
entists Fund (no. 50225520) is greatly appreciated.
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