Abstract

In this paper a multi-stage numerical analysis is presented with the aim to investigate effects of forming on the high-cycle fatigue performance of a deep-drawn aluminum sheet structure for use in a floating photovoltaic system. Forming simulations of a subsection of the full geometry are performed in a realistic two-step drawing-springback cycle. A simplified global analysis of service load response is performed to obtain displacements at the submodel boundary, that are used to generate boundary conditions for a local service load analysis. The local analysis is then performed on three different models of the subsection: (I) excluding forming effects, (II) including effects of thinning, and (III) including effects of thinning and residual stresses. The critical location with respect to the fatigue limit criterion in the Ottosen-Stenström-Ristinmaa high-cycle fatigue model was identified for case (I), and this location was used to compare the different models to assess effects of forming on high-cycle fatigue performance. Furthermore, the dynamic friction coefficient , and the isotropickinematic mixing coefficient were varied in order to investigate their respective effects.