Abstract

Roll-bonded stainless steel/aluminum laminates are increasingly used in lightweight structural applications; however, their deep-drawing behavior and thickness evolution remain insufficiently understood due to the mechanical mismatch between constituent layers. This study investigates the deep drawing of a SUS304/AA1050/SUS430 laminated sheet through a combined experimental and finite-element approach. The laminate was manufactured by roll bonding and exhibited sound interfacial integrity without observable delamination. To account for load transfer and deformation compatibility among the bonded layers, the material was modeled as an equivalent homogeneous laminate whose constitutive response was identified directly from tensile tests performed on the three-layer sheet. Full-field strain measurements were obtained using digital image correlation (DIC), and anisotropic plasticity was described using the Hill48 yield criterion combined with Swift and Voce hardening laws. Numerical predictions were validated against experimentally measured thickness distributions in cylindrical cup deep drawing. Among the investigated constitutive models, the Voce-RD0 calibration provided the closest agreement with experimental results. The validated model was subsequently employed to evaluate the effects of blank holder force, punch–die clearance, and die radius on thickness evolution. Based on the systematic parametric investigation, the combination of a blank holder force of 14 tons, a punch–die clearance of 3.2 mm, and a die radius of 10 mm yielded the most uniform thickness distribution among the conditions investigated. Under these conditions, localized thinning was reduced and the thickness distribution became more uniform. The finite element predictions agreed well with the experimental measurements, with deviations below 3%. The proposed experimental–numerical approach offers a practical framework for constitutive characterization and process parameter selection in the deep drawing of roll-bonded multilayer sheet materials.

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